industrial coating plants impianti di verniciatura industriale
spray booths for car body shop cabine di spruzzatura per carrozzeria
sandblasting booths cabine di sabbiatura
all the load-bearing structures of our coating plants are realised in aluminium tutte le strutture portanti dei nostri impianti di verniciatura sono in alluminio
industrial coating booths cabine di verniciatura
YOU CAN SEE MORE THAN 1000 PHOTOS AND VIDEOS
A new line of nanotechnology conversions for corrosion classes C3H - C4H - C5M
DOLLCOAT RS 103 is the first product in a new family of surface conversions for high-performance processes. It gives pre-treated surfaces extremely high-quality protection and corrosion resistance, whatever the nature of the paints used.
MAIN FEATURES
Multimetal no rinse product to be used at room temperature.
Applicable with nebulisation modules, through traditional recirculating or immersion nozzles.
Excellent pre-cataphoresis treatment.
European Coatings Show: 25 – 27 March 2025
European Coatings Show Conference: 24–26 March 2025
the Art in PFAS Removal in Painting Applications
rotoli, pannelli e celle in fibra di vetro
celle filtranti per alte temperature
rotoli e pannelli in fibra sintetica
accumulatore
vernice “Columbus”
filtri “Andreae”
cartucce filtranti
filtri assoluti
applicazioni speciali
rolls, panels and cells of glass fiber
filtering cells for high temperatures
rolls and panels of synthetic fiber
paint accumulator “Columbus”
“Andreae” filters
filtering cartridges
absolute filters
special application
distributori esclusivi per l’Italia
massima efficienza
massimo accumulo di vernice
massima durata
minori costi di smaltimento
rispetto ai filtri oggi in commercio =
minori costi di manutenzione
L’esclusivo design alveolare permette di trattenere quantità di overspray notevolmente superiori
FOCUS ON TECHNOLOGY
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FOCUS ON TECHNOLOGY
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Coating of 3D-Printed Aluminium Components for Architecture
BREAKTHROUGH The New Dimension in CMF Design: TIGER Digital Finishes Revolutionise Creative Processes
ON TECHNOLOGIES
Metalux: Pioneering the Adoption of Pre-Treatment Nanotechnology with Dollcoat RS 103
Spa
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WITHIN SURFACES
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#EOS15: eos Mktg&Communication, the Publisher of the ipcm® Magazines, Celebrates 15 Years in Business
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Assovernici’s New Sustainability Report
Charts the Path to an Environmentally and Human-Friendly Transition
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Automated Cleaning Process for Printed Photovoltaic Modules Manufactured Using Roll-to-roll Technology
COLOUR STUDY
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Purple: a Colour Rich in Symbolism and History
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Cleaning Inner Surfaces of Complex Parts with Snow Jet Technology 206
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ROUTING: the Theme of BASF’s 2024-2025 Automotive Color Trends Collection
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174 UCIF INFORMS
ANIMA Confindustria: a New Office in Brussels to Strengthen the Italian Mechanical Engineering Industry’s Presence in Europe 182
THE INDUSTRY 189 ICT - INDUSTRIAL CLEANING TECHNOLOGIES 190 INDUSTRY NEWS - ICT
192 HIGHLIGHT OF THE MONTH - ICT
Customised Industrial Cleaning Processes: Fismet Service’s Philosophy
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Alessia Venturi Editor-in-chief Direttore Responsabile
Few other natural phenomena are as universal and democratic as corrosion. When I think about it, the only ones that come to my mind are those related to decay, from illness to death.
In fact, corrosion is itself a phenomenon of decay, of material degradation. An unstoppable process that tends to return metals to their original state.
As a natural event, corrosion cannot be completely eliminated but only controlled, limited, or prevented. Its impact on industry and civilisation is so significant that estimates from different sources put it at between 2 and 6% of the GDP of the world’s largest nations.
Corrosion contributes to environmental pollution, is dangerous to human health, and conflicts with sustainability because it destroys rather than preserves.
Product durability has become so crucial that corrosion resistance is the main performance element required of a coating system in general industry today, also in light of climate change and the increasing rate of pollution, which subject paints to ever-increasing stress, thus limiting their service life.
Such a widespread demand for greater durability of coatings characterises all industrial segments indiscriminately, and the articles in this year's last issue, primarily devoted to technology trends for surface treatments in the ACE sector (agricultural, construction, and earthmoving machinery, and more generally all off-road vehicles) bear ample witness to this. Corrosion needs three elements to occur: an electrolyte (water), an electron acceptor (air), and a metal exposed to them. To prevent or slow it down, one of these three conditions must be eliminated, and this is precisely the role of any coating or lining system: to act as a barrier between the substrate (metal) and water and air.
Be they cataphoresis, liquid, or powder paint products applied in one or more layers, organic coatings protect metals against degradation to different degrees and with varying durability rates. The trend towards ever-higher corrosion resistance, together with the demand for sustainability, is the main driver of development in the industrial coating sector. A coating system that includes a cataphoresis primer and a powder or liquid top coat is one solution – the most effective one – for ensuring maximum component durability. That is why cataphoresis is gaining ground in new fields, breaking out of the ivory tower of the automotive and component industry.
To meet the demands for durability and resistance, it is imperative for any company in the coating sector to have application lines and processes that are up-to-date with the latest technology, hyper-controlled, and tracked to also ensure consistency among batches. Preventing corrosion saves money, preserves human and environmental health, and is one of the highest forms of sustainability.
With the hope that market and industry trends in the new year will enable companies to keep innovating to this end, I would also like to take this opportunity to wish all our readers Happy Holidays!
The new Advanced Materials and Coatings Lab of HII will develop and produce cutting-edge thermal coatings for the aerospace industry.
The Mission Technologies division of the all-domain defence provider HII has recently announced the opening of its Advanced Materials and Coatings Lab facility in Willowbrook (Illinois –United States of America), that will be dedicated to developing and manufacturing cutting-edge thermal coatings for the aerospace industry – including Government and commercial space programmes as well as satellite providers.
The opening of the new laboratory, which replaces the site previously located in downtown Chicago, underscores the commitment of the company to advancing the science of space coatings and supporting even the most ambitious space endeavours. As a matter of fact, the new 13,250 square foot (1,231 m2) area will feature dedicated laboratories for customised tasks, enabling the company experts to focus solely on research and development without constraints. The premise is designed to enhance pioneering technology for interplanetary and manned missions to the International Space Station (ISS) by creating specialised coatings technologies that meet the evolving needs of modern spacecraft, space systems and components. The facility is then equipped with the latest chemical laboratory technology, including large-scale solution preparation equipment, hightemperature furnaces and advanced powder processing machinery, enabling the engineers, chemists and technicians of the Mission Technologies division to continue developing coatings that are precisely engineered for specific applications in space and other challenging environments. In addition, it will also allow the team to expand their specialty coating research and manufacturing into other DOD applications and solutions.
“Our new Advanced Materials and Coatings Lab represents a significant investment in the future of aerospace technology: this facility will allow us to push the boundaries of innovation, continuing our work in developing unique coating materials that protect aerospace structures and NASA astronauts from the challenging space environment,” has declared Grant Hagen, the president of the Cyber, Electronic Warfare and Space business group of Mission Technologies. The new laboratory will leverage the six-decade legacy of HII in supporting NASA space programmes, the U.S. Department of Defense and other key partners in the aerospace sector.
Since 1961, the company has in fact has been at the forefront of developing advanced coatings to protect spacecraft and satellites from the harsh conditions of space, including solar flares, radiation and extreme temperatures.
“We are incredibly proud of the expertise and dedication of our team. Every coating we develop is a testament to their skill and commitment to excellence, ensuring that every spacecraft we touch is protected and ready to face the challenges of space. We look forward to welcoming our partners and clients to our new facility and demonstrating how our enhanced capabilities will benefit the future of space exploration and defence,” has added Jeff Showalter, the vicepresident of operations for Mission Technologies and manager of the Advanced Materials and Coatings Lab.
For further information: www.hii.com
Strategic investment of Covestro focuses on sustainable solutions and advanced digital capabilities.
Covestro has announced a significant investment of approximately €100 million in its global R&D infrastructure, aimed at enhancing its innovation capabilities and securing future competitiveness through 2025. This investment will support the development of sustainable technologies, particularly in core industries such as automotive and construction, and facilitate the transition towards a full circular economy.
“Our investments in R&D are integral to our strategy of creating value for our customers. They are enabling us to expand and maintain our innovation pipeline at a high level. By this, we are the go-to partner for more sustainable solutions which help to meet the climate-neutrality targets of our customers. Thanks to this global innovation booster, we come even closer to our joint goal to become fully circular,” has stated Sucheta Govil, CCO at Covestro.
Key highlights of the investment include:
Digital R&D Simulations: Enhanced capabilities for researching recycling innovations and chemical processes to expedite the development of sustainable solutions.
In-Mold-Coating Expertise: Investments in facilities, particularly in Leverkusen, enhance innovation in InMold-Coating technologies, resulting in high-quality surfaces for automotive production.
High-Performance Computing: The implementation of high-performance computers (HPCII) in Leverkusen will accelerate research processes and enable efficient simulations, benefiting various applications, including energy-efficient refrigeration.
Chemical Recycling Initiatives: Projects like the Evocycle® CQ mattress initiative focus on innovative chemolysis technology for recovering key components from used polyurethane foams.
“Simulations of chemical processes are a key element in the development of recycling technologies and research on new molecule classifications. Moreover, laboratory digitalization enables test data to be recorded in higher quality and to a greater extent than is usual in analogue ways. Both help us to find the most possible and more sustainable solutions for our customers more quickly. Many developments in the field of recycling would be like looking for a needle in a haystack without digital R&D and simulations,” has added Torsten Heinemann, Head of Group Innovation & Sustainability at Covestro. Additionally, Covestro is modernising its laboratories in Leverkusen and upgrading facilities in Pittsburgh, USA, to support innovative research. The company’s investment in the innovation centre in Shanghai further demonstrates its commitment to leading solution developments for the automotive and electronics industries. Through these advancements, Covestro aims to deliver faster and more sustainable solutions for its customers while advancing its circular economy goals.
For further information: www.covestro.com/en
Brenntag, the global leader in the distribution of chemicals and ingredients, is celebrating its 150th anniversary with various initiatives, including the publication of the book “150 Years of Brenntag – From Berlin out into the World,” which traces the company’s history from its founding in Berlin in 1874 by Jewish entrepreneur Philipp Mühsam as an egg wholesaler. The book, the result of a twoyear research project led by historians Dr. Stephanie Tilly and Prof. Dr. Christopher Kopper, provides a detailed analysis of Brenntag’s transformation from a family business to a global market leader.
The company’s history is marked by significant milestones, such as its acquisition by the Stinnes Group in 1937 and its transition into chemical distribution. After World War II, Brenntag expanded internationally, and today it operates in more than 70 countries, serving over 180,000 customers with a wide portfolio of products and services.
The celebrations culminated in an official event in Essen, Germany, attended by notable figures, including German Chancellor Olaf Scholz, who highlighted the company’s adaptability and innovation.
“With respect and pride, we celebrate our history and the people, decisions, and challenges that have shaped our company and brought us to where we stand today. Throughout its journey, Brenntag has thrived. We have continuously adapted to new conditions and needs, driven by curiosity and showing pioneering spirit, while staying focused. We reflect on our past and gain deeper insight from the successes, setbacks, and experiences that guide us toward a responsible and successful tomorrow. In the spirit of our founder, Philipp Mühsam, Brenntag has always evolved and recalibrated. And we continue this tradition, actively shaping our markets as a truly global leader”, reaffirmed the company’s commitment Christian Kohlpaintner, Chief Executive Officer of Brenntag SE, during the ceremony with around 400 guests.
For further information: www.brenntag.com
Dr. Christian Kohlpaintner, CEO of Brenntag SE.
The new Chairman of CEPE’s Board, David Beckford, will enhance collaboration with the BCF in the paints and coatings industry.
CEPE has appointed David Beckford as Chairman of its board during the CEPE General Assembly in Copenhagen (Denmark). The Assembly also voted the new Board members, as well as the relationship between CEPE and the British Coatings Federation.
“It is an honour to take on this role and I would like to thank my counterparts for entrusting me with this position. I am committed to pursuing the work of Roald Johannsen to help our companies, especially smaller ones such as mine, navigate the evermore challenging regulatory landscape to ensure a sustainable future for our businesses and the environment,” has stated David Beckford, Chairman of CEPE’s Board.
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Additionally, a significant decision made during the General Assembly was to keep the UK within CEPE’s geographical scope through the adoption of a Memorandum of Understanding. This document outlines the principles and guidelines that govern the relationship between CEPE and the BCF, aiming to ensure ongoing and future collaboration by clearly defining the roles and responsibilities of each association.
“It has been a privilege to serve as CEPE Chairman and an honour to represent this great industry of ours. My thanks to the Board, CEPE staff and National Associations for their collaboration in refreshing our vision, mission and purpose during a period of much change. CEPE is in good hands under the leadership of David,” has added Roald Johannsen, Vice-President of PPG, who has served as CEPE Chairman since 2021. The General Assembly also confirmed the appointment of the following new Board members:
Brendan Catlow, Sherwin Williams
Pedro Serret-Salvat, PPG
Guillaume Fremaux, Heghebaert & Fremaux
Mehran Yazdani, Sun Chemicals.
For further information: www.cepe.org
The new Stellair™ and Stellair ACE air spray guns developed by Graco achieved the Ergonomics Performance Certification.
Graco has recently announced the launch of the new Stellair™ and Stellair ACE industrial air spray guns, that have obtained the Ergonomics Performance certification issued by United States Ergonomics after extensive and advanced testing – proving that the manual pressure feed sprayers reduce fatigue potential and increase productivity for industrial painters. The Minneapolis-based Graco Inc. is an international manufacturer of fluid handling equipment that produces and markets systems and technologies which move, measure, control, dispense and spray fluid and powder materials. Its Industrial division creates liquid finishing and advanced fluid dispense devices primarily for applying liquids on metals, wood and plastics, with a
special emphasis on solutions that offer easy integration to paint monitoring and control systems.
"From the beginning, the project team saw the importance of coater comfort. Retaining good coaters is a challenge for factories worldwide because of muscle stress and injury due to the repetitive motions of painting. That is why we engaged US Ergonomics and incorporated their research data into the Stellair and Stelair ACE design," has stated Wendy Hartley, Global Product Manager for the industrial division of Graco in North America. Although ergonomics has always been considered in previous designs, the company has now fully-recognised the importance of continual improvements by involving United States Ergonomics, a global consulting service and
product testing company that researched and evaluated manual air spray gun ergonomics at three critical stages: design analysis and optimisation, design review and testing and ergonomic assessment.
Features of the Stellair and Stellair ACE spray guns
The Stellair air spray gun is composed by an aluminium case weighing 410 grammes: compared to similar equipment, it lessens muscle exertion by up to 18%. Moreover, it minimises hand pressure points – improving overall gun balance – and enhances hose flexibility.
Thanks to its durably unique carbon reinforced polymer construction, the Stellair ACE gun weighs only 209 grammes –up to 50% lighter than the most common manual pressure feed sprayers. Furthermore, it uses up to 25% less muscle effort than comparable solutions.
“Painters consistently rated the new Graco paint sprayers superior in weight, hand fit, feel, balance, trigger control and adjustability. Their feedback was important to the Ergonomics Performance Certification and we expect field trials in production paint shop applications to fulfil formal certification requirements,” has commented Wendy Hartley.
For further information: www.graco.com
The heat pumps from Harter ensure a reliable drying process and a perfect energy balance.
For those who do not want to just dehumidify and recuperate heat but also dry without resulting exhaust air and save a maximum of energy condensation drying with a heat pump is the perfect solution. This drying technique shows a number of important aspects. One is the dehumidification process as such: products are dried by extremely dry air. This air is unsaturated and therefore quickly absorbs any humidity present. The basic version – without condensation – is to take in ambient air from the production area and, following drying, to release the now humidity-laden air into the production area again. This technique allows to recuperate a certain amount of heat for introduction in the process. A cross-flow heat exchanger is normally used for this purpose. The humid air, however, and also part of the heat enters the production area.
If, alternatively, a heat pump is used for this process, the air circuit may be closed completely. The humid air is cooled. The humidity condenses
to form water. The water leaves the heat pump. The air is reheated and returned into the circuit. Using condensation drying the energy is recuperated completely. This creates a permanent circuit that is closed. Closed meaning exhaust air free. And independent of the climate and the seasons.
Using heat pump technology means not employing any external air. The only air employed is the process air inside the closed system. Using a heat pump relieves the need for additional heating of the ambient / process air to reach the required process temperature. Temperature control is also much easier. The products are ultimately dry and their surfaces free from staining. The air is clean and the employees are content. The process is reliable and the energy balance is perfect.
For further information: www.harter-gmbh.de/en/
The new FutureLab from Beckers will support the future development of sustainable coil coatings.
On 26th September 2024, Beckers Group held the grand-opening inauguration of its FutureLab, a new state-of-the-art facility in Liverpool (United Kingdom) hosting an innovation centre that will foster the future development of the next generation of sustainable coil coatings. The event included presentations, tours of the new facility and discussions on the next innovations of the business.
The new building will effectively double the capacity of the longterm development department of Beckers, enhancing its ability to manufacture more environmentally-friendly coatings through new pieces of equipment and devices. Furthermore, the site features the thermal-control coatings from the company on the roof, reducing the amount of energy needed to heat the premise, while an active carbon filtration system on a Volatile Organic Compounds exhaust chimney and several heat pumps will decrease the CO2 emissions.
“These features not only enhance the functionality and efficiency of the FutureLab, but also align with our commitment to pioneering positive
impact and innovation in the industry,” has stated Gavin Bown, the Chief Technology Officer of Beckers. “FutureLab represents a significant leap forward in our commitment to innovation and sustainability: this state-of-the-art facility embodies our dedication to pioneering new technologies and sustainable practices that will lead the coatings industry into a brighter and more responsible future. I am thrilled to inaugurate FutureLab and excited for the groundbreaking work that will emerge from here.”
The centre also aims to act as a hub for creativity, collaboration and joint research, while contributing to society by promoting education and local job opportunities. Moreover, a personalised experience room will welcome all customers and partners who are keen on collaborating with Beckers on future developments, such as the enhancement of UV/EB coatings.
For further information: www.beckers-group.com
The new Bonderite C-AK 24600 from Henkel boosts efficiency and sustainability in aluminium alkaline etching, saving energy and increasing performances.
The specialty chemicals manufacturer Henkel has recently presented Bonderite C-AK 24600, a new solution specifically developed to either save energy or increase alkaline etching performances during the pre-treatment of aluminium for architectural applications.
As a matter of fact, depending on the system configuration, the user can either increase the etching rate while maintaining the same application temperature or reduce it while maintaining the same etching performances.
Alkaline etching allows to create a rough surface that ensures the adhesion and the performances of the subsequent conversion coating. Traditionally, users have achieved the highest etching performances at a higher temperature, consuming a lot of energy.
The new product Bonderite C-AK 24600 from Henkel
allows to reduce the temperature by up to 7 °C while still achieving the required etching rate – saving more than 0.5 tons of CO2 in natural gas per cubic meter of bath.
“Bonderite C-AK 24600 shows how innovation in the chemical industry can help reduce environmental impact and increase efficiency in the production chain. We are enabling our customers to achieve their sustainability goals, such as energy savings, or in other words, to achieve more with less. This was not possible with previously available products because they required a higher temperature to achieve the desired performance,” has stated Cristina Acedo, the senior product development manager of Henkel.
For further information: www.henkel.com
In alkaline etching of aluminium for architectural applications, Bonderite C-AK 24600 can save energy or increase etching performance, depending on the system configuration.
The measuring instruments from Krüss will use a new dosing system to quickly measure the retraction behaviour of dosed drops.
Many industrially relevant surface properties – such as coatability, cleanliness and adhesiveness – are directly or indirectly linked to wettability, which is therefore often tested as part of quality assurance controls. In contrast, dewetting (i.e. the contraction and possible run-off of the liquid from the material) has rarely been investigated, even though its behaviour is particularly informative for many materials, such as hydrophobic and self-cleaning surfaces.
Moreover, dewettability also reacts sensitively to material pre-treatment and it is therefore an ideal test criterion. The result relevant for dewetting is the so-called receding angle, a variant of the contact angle. The measuring instrument manufacturer Krüss has now developed the Stood-up Drop for the optical measurement of the receding angle.
As a matter of fact, the Hamburg-based (Germany) company Krüss has recently announced that its contact angle measuring instruments will use a new dosing system to measure the retraction behaviour of
dosed drops in a matter of seconds. The new method developed by the international provider of measuring instruments for surface and interfacial tension complements conventional contact angle methods and expands the application possibilities of wetting measurement for testing material surfaces.
The new dosing unit for the Stood-up Drop method places a drop of water on the sample with high and controlled dynamics. The liquid initially spreads out flat and then contracts at lightning speed to form a defined drop. A camera then captures the drop in a video image, which is analysed to determine the receding contact angle within seconds.
The potential of the new Stood-up Drop dewetting method
Measuring the receding angle has the potential to supplement or even replace other test methods for surfaces: in extensive preliminary investigations, the results have shown good correlations with pretreatment parameters, such as for corona, plasma and flame treatments – but also with the results of common test methods.
For example, pre-screening with the receding angle has already reduced the amount of elaborate material testing in applications like the measurements of the Moisture Vapor Transmission Rate (MVTR), employed to quantify moisture protection and breathability. Since the measuring sequence and the dosing parameters are predefined, the results are user-independent. Furthermore, thanks to the speed of the new approach, the receding angle can now be used for quality tests even with large numbers of samples. Finally, as it does not use any harmful substances, it is also safer than using test inks whose areas of application overlap with those of the Stood-up Drop.
Krüss is offering a free three-part webinar on the new Stood-up Drop method, in order to provide more in-depth information on the wide range of possible applications.
For further information: visit.kruss-scientific.com/webinar-stood-up-drop-general
Alessia Venturi ipcm®
In 2024, Savim Europe chose to celebrate its 40th anniversary in a unique and engaging way, offering its employees a series of events inspired by the four elements: water, earth, wind, and fire. The celebrations culminated on 4 October with an event combining art, culture, and entrepreneurship.
Culture, history, and business were the focus of the event that celebrated Savim Europe’s 40th anniversary in the evocative setting of Palazzo Maffei in Verona, Italy, on 4 October. A leader in the design and installation of industrial coating systems, this company was founded by Renzo and Laura Scavini precisely in Verona in 1984, and it is currently run by their children Marina, Francesco, and Nicoletta. The evening was attended by long-standing and new partners alike, underlining the strength of the connection among Savim Europe, the Verona area, and its entrepreneurial culture. It was an opportunity to reminisce about the company’s achievements but also to look at its future with a view to innovation and sustainability. Some of Savim Europe’s most recent developments were presented with this in mind,
including the upcoming publication of its first sustainability report in line with its future-oriented vision.
Marina Scavini, the CFO and President of the Board of Savim, highlighted the importance of this celebration: “This anniversary is a significant moment for us: we are celebrating forty years of history, a journey started by our parents. My brother, my sister, and I are deeply moved because it is about the history of our family as well as of the company we have built together. Celebrating in the heart of our city was a symbolic choice, as Verona embodies centuries of culture, ingenuity, and art, inspiring us every day in our work. We want to continue pursuing excellence, ensuring that what we create today will last for a long time and have a meaningful impact.”
Nicoletta Scavini, the company’s HR and Quality & Safety System Manager, also emphasised Savim’s commitment to sustainability: “Over the years, we have always paid great attention to the environment and the community in which we operate. We are particularly proud to announce the publication of our first sustainability report in our fortieth year of activity. This document not only celebrates our past and achievements but also represents our concrete commitment to a more responsible and innovative future.”
To celebrate this important anniversary, Savim organised a series of special events dedicated to the four elements of nature over the spring and summer. It was called SAVIM 4.0 and involved all its employees, the beating heart of the Savim family – to whom the company always pays a lot of attention also through projects aimed at improving their working days, such as company snacks, book exchanges, and workshops for children during the pandemic period1
1 A. Venturi “Savim: A Successful ESG and CSR Model for Italian Small and Medium Enterprises”, in ipcm® Vol. XV, no. 85 January-February 2024, pp. 88-92
The four elements, symbols of nature and primordial force, were the leitmotif of a celebration that highlighted what is truly essential: the people and values that have made Savim Europe a successful business. The first of the four events, dedicated to the element of water, took place on 11 May, with an unforgettable rafting experience on the Adige River in Verona. The company’s employees and their families gathered for a day of sport, history, art, and fun. Each boat was led by an experienced F.I.Raft guide to guarantee everyone’s safety while allowing them to admire the most enchanting corners of their beloved city. This experience offered a unique and fascinating perspective of Verona while strengthening ties within the large Savim Europe family. The second event, dedicated to the element of earth, was a trek in the Lessinia area near Verona. Savim’s employees and their families explored the villages and forests around Bosco Chiesanuova, combining sport, history, and fun. Three environmental guides accompanied the groups along the route, ensuring safety and illustrating the stories, customs, and natural features of the places they passed through. The day ended with a convivial lunch at the brewery Agribirrificio Laorno, where participants shared the emotions of the experience and
celebrated together. The children also enjoyed a treasure hunt, making the day even more special.
The Midsummer event, dedicated to the element of wind, was a tribute to all those who have contributed to building the company’s history.
This time, the Savim Europe team immersed themselves in the theme with a magical sunset cruise on Lake Garda on 19 July, enjoying a unique experience on board a boat while exploring the wonders of the lake as the sun set on the horizon. The pleasant breeze and the breathtaking panorama made the evening unforgettable. The cruise was the perfect opportunity to relax and appreciate the natural beauty of the area while enjoying a delicious aperitif and dinner on board; the evening was characterised by laughter, music, and moments of sharing, reinforcing the team spirit and friendship among employees. Unforgettable was the strong wind that accompanied Savim’s adventure on Lake Garda, making it even more exciting and fun.
The cycle of celebrations ended on 7 September with an event dedicated to the element of fire, the protagonist of a barbecue at a craft brewery, a convivial event attended by employees and their families. Fire, the symbol of passion and energy, warmed the atmosphere of
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this evening in the name of sociability, where good food and craft beer provided the backdrop for a moment of collective celebration.
These four events were not simply symbolic celebrations but rather a key opportunity for Savim Europe to reaffirm its values and strengthen the bond between the company and the people who make it work every day. The hallmark of these celebrations was the choice to involve all employees and their families, recognising how essential family support is to build a solid and fulfilling career – an approach demonstrating a profound awareness of the role the internal community plays in a business’ success.
Water, a symbol of adaptability and flexibility, celebrated the company’s ability to meet the ever-changing challenges of the industrial market.
Earth, with its solidity and stability-related meanings, represented the foundations on which Savim has built its success, rooting its values in tradition and reliability. Wind, synonymous with change and innovation, symbolised the company’s desire to look ahead, evolving and constantly seeking new ways.
Fire, finally, recalled the passion that has been fuelling the vision of the Scavini family and all the company’s employees, pushing them to overcome obstacles and achieve new goals.
The concluding event held at Palazzo Maffei in Verona’s Piazza delle Erbe – devoted to business since the time of the ancient Romans – on 4 October was a touching celebration of the many achievements of Savim Europe and the Scavini family, closeknit as never before. At the same time, it was an opportunity to look at the past and the Veronese entrepreneurial culture, one of the added values of this geographical area, together with some exceptional guests.
“My brother, my sister, and I were very excited at the idea of honouring a piece of our history here in Verona,” said Marina Scavini during an interview with Verona Network during the evening. “Celebrating in this place was a significant choice because this city is rich in history, a crossroads of cultures and civilisations, as proven by all the monuments and archaeological sites visited by thousands of people every year. These express not only beauty but also an ability to build, the engineering skills of the civilisations that have inhabited Verona – from the ancient Romans to the Medieval Communes’ society, from the great Renaissance families to the period of the Republic of Venice. We are inspired by this land and its history to continue to cultivate the values of competence, of beauty, of attention to detail, but also of safety and of doing things well to make them last.”
“We decided to title this celebration ‘Colours beyond epochs: from ancient art to modern innovation’ to acknowledge art as avant-garde, as innovation, as the ability to break the mould,” explained Nicoletta Scavini. “Above all, we wanted to celebrate this 40th anniversary with our employees, for whom we organised a series of events themed around the four elements of nature to create moments of conviviality but also a synergy with the Verona area. And the culmination of these celebrations, the evening of 4 October, highlighted another vital element of our region: art.”
Among the speakers at the afternoon conference, masterfully moderated by University Professor and business consultant Franco Cesaro, was also the President of Museimpresa Antonio Calabrò, who emphasised the importance of history as an asset of competitiveness in the business world: “For a person as well as for a company, history can coincide with pride in what one has done, perhaps with a touch of melancholy, but it is also awareness of one’s roots and one’s ability to stay in the markets over time. History is a competitive asset. And why is that? Because it is an economic value. Because in a world where competition is very selective and severe, being Italian means having a sense of beauty and, at the same time, a great ability to work with new technologies embedded within your spirit. Memory and innovation: history is a lever to enhance these qualities.”
The event also included speeches by Daryush Arabnia, the President of UCIF, the Italian Surface Treatment Equipment Manufacturers’ Association, of which Savim is an active member, who reflected on the metaphor of the company as an orchard to be cultivated over time; Anna Bedoni, museum educator of the Civic Museums of Verona, who offered an insight into the entrepreneurial liveliness of the city over the centuries, from the exploitation of the Adige River to manufacturing developments and the intense trade with transalpine countries and other Italian territories, through the description of
buildings, monuments, and archaeological sites that can be found in Piazza delle Erbe or nearby it; and, Stefania Toaldo, the Planning and Development Manager of the Monteverde social cooperative, with which Savim has been collaborating for years2, who confirmed the desire of Savim and the Scavini family to give back to the local community, not by obligation but by choice. After the conference, the participants had the opportunity to take a guided tour of the Casa Museale Palazzo Maffei, which houses works by famous artists from all eras, up to the most futuristic contemporary digital works. Finally, the aperitif with music in the lively Piazza delle Erbe and the placée dinner at Maffei restaurant were a fitting conclusion to a special anniversary celebration.
ipcm® would like to wish Savim Europe a future as bright as its past and present.
Oliver Zanner,
FreiLacke - Emil Frei GmbH & Co. KG, Bräunlingen-Döggingen, Germany
FreiLacke system coatings make additional anti-graffiti protection coatings on rolling stock superfluous. An independent testing institute has now confirmed this and consequently cleared the way for authorisation by German Rail company Deutsche Bahn. The system coatings have also been successfully used in service operations for the last three years by public transport company Berliner Verkehrsgesellschaft (BVG).
EUR 12.1 million: such is the cost incurred by Deutsche Bahn in 2022 for damage caused by graffiti. One sixth of this sum was apportioned to regional and light railway trains in Berlin and Brandenburg alone. Berliner Verkehrsgesellschaft (BVG) is also no stranger to this problem. Damage from vandalism amounts to between four and five million euros annually, one million of which is caused solely by graffiti.
Graffiti appears on floors, walls, interior parts and, above all, in the toilet facilities. Railway companies, BVG and many other operating companies have increased video surveillance in the trains to deter and identify the
perpetrators. In addition to that, foils and coatings are applied in railway stations, protective film is put on window panes and vehicles are coated with a transparent protective coating. The latter makes it easier to remove graffiti and tags – texts written with thick marker pens.
The protective coatings have to fulfil two functions: they need to be resistant to regular use of what are sometimes harsh cleaning agents and must also enable easy removal of graffiti and other types of fouling. Coating quality expectations are high, as components on trains and
U-Bahn (underground rail system) rolling stock are subject to the high stress factors of conventional operation. “A service life of at least ten years is stipulated in terms of surface durability, while the trains themselves need to last up to 40 years,” said Dr Hilmar Weisse, sales manager at FreiLacke.
U-bahn rolling stock and trains are cleaned on an almost daily basis inside, while the outside is normally cleaned once a week in a train washing facility.
“The credo here is: the better the surface, the easier it is to remove graffiti. If the coating has open structures, it becomes difficult,” explained Dr. Christian Bohne of DBS. To remove all the fouling quickly and effectively, operators use powerful and sometimes aggressive cleaning agents. Graffiti must essentially be removed by hand, which cannot be done in train washing facilities or cleaning machines. Train conductors therefore carry special cleaning wipes to quickly wipe off graffiti as best they can.
“An alternative is to apply a special graffiti remover akin to standard paint stripper to the area in question,” said Weisse, “a process that frequently has to be repeated several times, which is extremely strenuous for employees due to the high level of physical exertion and, unfortunately, also often raises health issues because of the solvent vapours.” The so-called ‘artists’ are not aware of the slew of labour and costs they trigger with their hastily scribbled tags and graffiti, and that ultimately, it is real people who have to pay the price. The clean-up work is also generally harsh on the surfaces.
As an operating company, Deutsche Bahn imposes specific coating standards on manufacturers such as Stadler, Siemens and Alstom. For example, standard DBS 918300 applies for liquid coating and standard DBS 918340 for powder coating. Powder or liquid coatings used in passenger compartments are subject to the specifications in DBS Sheet 38. When Deutsche Bahn acquires powder-coated parts, the coatings have to meet DBS 918340 standards. This guideline specifies how a powder coating is to be tested to ensure it meets specific parameters for the interior or exterior coating of technical or decorative components. The DBS qualifies the manufacturers’ coating systems and also provides recommendations for the railway sector. For example, when the inter-city rail service buys new ICEs, the DBS helps with the requirement specification, sets out a coating plan and specifies the respective DBS quality level. And when a rolling stock operator requires, for example, enhanced graffiti protection, the DBS provides recommendations.
Deutsche Bahn requirements fulfilled
The two lists of DBS-qualified coatings currently encompass around 230 coatings from various manufacturers (as at July 2024). However, only one powder and liquid coating combination additionally meets the requirements stipulated in Sheet 50 ‘Technical Terms of Delivery for Coating Materials for Rail Vehicles’: the FreiLacke system coating comprising Freiotherm PZ5 powder coating and DC1983 liquid coating. ‘This product also meets the requirements in Sheet 50 of DBS 918300 regarding the barrier effect, resistance to cleaning agents, graffiti removal agents and repeated removal of graffiti’, as stated in the product qualification document issued by DB Systemtechnik. As such, with PZ5 and DC1983 no softening, swelling, cracking, peeling, ink residue or ‘shadowing’ occurs. Repeated removal of graffiti leaves no residue or discolouration. Furthermore, multiple layers of powder and liquid coatings can be applied without adherence problems when repairing or recoating.
No additional permanent protection needed
“A separate protective coating is no longer necessary, as our coating systems already provide protection. They also meet the stringent railway requirements stipulated in Sheet 50, as has now been confirmed by an independent institute,” reported coating specialist Weisse. In developing PZ 5 and DC1983 as a system coating comprising powder and liquid coatings, we applied the best available technology using an exceptionally high-quality polyurethane to provide optimum protective performance for our customers.
Solvent-based, 2-component polyurethane top coat with isocyanate hardeners for rail vehicles and components, providing excellent light and weather resistance on primers and fillers. In addition to DBS 918300 Sheet 38, the product also meets the requirements regarding barrier effects, resistance to cleaning agents, graffiti removal agents and repeated removal of graffiti stipulated in DBS 918300 Sheet 50.
PUR-based powder coating for decorative interior application, rail vehicles and components, providing excellent temperature and chemical resistance on primers and fillers. In addition to DBS 918 340, the product also meets the requirements regarding barrier effects, resistance to cleaning agents, graffiti removal agents and repeated removal of graffiti stipulated in DBS 918300 Sheet 50.
For three years, BVG in Berlin has been using PZ5 powder coatings on handrails, ceiling panels, seat trim covers, lighting and inside the doors, while the door columns made of glass-fibre reinforced plastic in U-Bahn rolling stock are coated with the colour-coordinated liquid coating.
The coatings are already being used by rail vehicle manufacturer Stadler in Berlin and its suppliers: “PZ5 is highly cross-linked and therefore very dense, making it extremely durable and resistant to chemicals, even against aggressive cleaning agents,” said quality manager Kevin Sloniecki, the specialist engineer responsible for surface technology at Stadler.
The certified Frosio coating inspector also develops coating standards and is responsible for vehicle body coatings. “PZ5 also complies with Stadler internal standards and provides a high level of corrosion protection when it comes to washing facilities and cleaning residues.”
What does his team particularly like about FreiLacke? “Its flat structures and the fact that you’re not wholly reliant on the salesperson, but can speak directly to the technicians,” said Sloniecki.
The PZ5 DC1983 system coating is now also being used by other rail vehicle manufacturers,” said Weisse. Of one thing he is sure: no other coating system on the market offers such an enormous performance capability; and consequently, provides such effective protection against graffiti and tags, while also helping railway operators to sustainably save on costs, time and labour.
FreiLacke system coatings do away with the need for additional layers to protect rail vehicles against graffiti.
CHEMTEC’S technologies are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity.
CHEMTEC develops customized solutions that aim to maximize the customer’s satisfaction.
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The RoDip® consumes much less water, fewer chemicals, and less heating energy than other technical solutions since the conveyor system does not require inclined tank entrances and exits.
The new paint shop for electric vehicles of Stellantis will also be equipped with the EcoInCure electric ovens from Dürr.
Stellantis is expected to double overall capacity at its Kenitra site with a new turnkey paint shop from Dürr. The advanced production technology allows for environmentally friendly and energy-saving high-quality electric car coating. Additionally, paint robots from other plants in the group are being repurposed to conserve resources, too.
The new plant in northwest Morocco is intended to be a model for energy optimization, while simultaneously significantly increasing Stellantis’ production capacity for battery-powered vehicles and hybrid models across the Peugeot, Citroën and Fiat brands. The newly designed
paint shop can handle 30 bodies per hour, a rate identical to the first Kenitra plant, which Dürr built in 2019.
Conserving water, chemicals, and heating energy Stellantis opted for Dürr’s patented RoDip® rotational dip process for pretreatment and cathodic electrocoating. This innovative method rotates the bodies around their axis, providing exceptional corrosion protection since the dip curves can be individually adapted to different body types, optimizing the immersion, flooding, and draining process. RoDip® consumes much less water, fewer chemicals, and less heating
energy than other technical solutions since the conveyor system eliminates the need for inclined tank entrances and exits. This shortens the immersion tank length by up to six meters and reduces tank volume. Lower energy and material consumption also reduces operating and unit costs.
Forty percent fewer carbon emissions
In addition to electrocoating, the Stellantis Group will debut the EcoInCure electric oven featuring innovative air flow conduction that heats and cools car bodies evenly from the inside out. This unique design reduces thermal-structural stresses and lowers car body heating time by up to 30 percent. The latest generation of the EcoInCure in the Kenitra plant makes fossil-fuel independence possible by operating with green electricity for an environmentally-friendly approach. Compared with its gas-powered counterpart, the electric EcoInCure reduces paint shop emissions by 40 percent, significantly reducing the carbon footprint.
Repurposing for optimum resource use
Stellantis is also enhancing efficiency by adopting wet-on-wet technology, saving both time and energy. The extensive process, which includes two-tone painting across three exterior painting stations, utilizes robots and application technology from existing Italian plants. These robots are equipped with EcoBell2 applicators to integrate seamlessly with existing equipment. In addition, technical equipment, such as air supply units, heaters, and conveyors, are being transported from Europe to Morocco for reuse. Repurposing production technology purposed from other plants is a sustainable approach that maximizes resources. In addition, repurposing is a suitable building block for constructing a paint shop within challenging time and cost constraints, all without compromising coating quality and performance.
For further information: www.durr.com
The shot blasting solution of Rösler will enhance Alupress’s production efficiency, while maintaining the high-quality finish required for complex components used in electric vehicles.
Due to rapidly growing demand for components for electric vehicles, Alupress GmbH, a renowned manufacturer of innovative aluminium and magnesium die-castings, had to increase its shot blasting capacity. For this purpose, the company purchased a continuous feed spinner hanger blast machine, including a power & free transport system, from Rösler. The custom-engineered equipment design guarantees effective but also gentle de-flashing of the work pieces without the risk of warping. Aluminium, with its relatively low bulk density, allows significant weight savings in the production of components for electric vehicles, resulting
in an expanded operating range of the battery. Therefore, the number of components produced from this light metal, made by die-casting and other production methods, is rapidly growing. Another goal for components for electrical vehicles is to create complex but, at the same, thin-walled designs, which allow additional weight savings. This also applies to the housings for different control devices manufactured by Alupress GmbH in Hildburghausen (Germany). At the Italian subsidiary of the Alupress AG in Brixen the growing demand from the automotive industry necessitated the investment into a new shot blast machine that was specially adapted to the strict customer requirements.
Automated all-around solution minimises the risk of work piece warping The shape and wall thickness of the aluminium and magnesium die-castings demanded a shot blast process that treats the components gently without warping them. At the same time, the shot blast operation had to be quick and run fully automatically. After the shot blast process the components pass through a cleaning device and, before they are packed and shipped, they undergo a quality control check. Therefore, besides the shot blast machine, the project scope also included a transport system that conveys the components automatically through the de-flashing and cleaning stations. Alupress chose Rösler as partner for this important project because of the convincing quality and productivity of the equipment as well as the excellent after-sales service. Another reason for working with this supplier was that Rösler had proven its technical competence in processing delicate work pieces in another, similar
project. Moreover, for many years Alupress has utilized shot blast machinery from Rösler and, therefore, knows the quality, productivity and reliability of this equipment.
To ensure gentle but also fast and effective de-flashing in continuous flow, the continuous feed spinner hanger shot blast machine, model RHBD 13/18-So, is equipped with eight special turbines, each with an installed power of 11 kW. The turbines contain extra wide throwing blades generating a particularly broad blast pattern. Furthermore, contrary to the standard placement of the turbines on one side of the blast chamber, the turbines were placed on both sides. This duplex turbine placement, together with the broad blast pattern, generates a gentle blast operation, which significantly minimizes the risk of warping. But the comparatively high blast media throughput, needed for efficient de-flashing and cleaning the light metal components, ensures a fast and effective shot blasting operation. Another feature for preventing work piece warping is that the work piece carrier, holding 60 to 80 components, not only rotates during the entire shot blast process but also oscillates back and forth in three positions. This guarantees that flashes and burs are safely removed, even in difficult-to-reach areas like
undercuts. To prevent the blast media – very small aluminium cut wire –from being sucked out of the shot blast machine by the exhaust air flow and to maintain the required optimum operating mix, the dust collector and the cascade air wash separator were technically modified. Of course, the wet dust collector is in full compliance with ATEX requirement. Necessary maintenance work is facilitated by multiple connections for cleaning equipment at different sections of the shot blast machine.
A power & free handling system ensures easy and trouble-free transport of the work pieces. At the load/unload station the height of the work piece carrier can be adjusted to the height of the respective operator, thus allowing ergonomic and comfortable working conditions. Moreover, generously laid-out buffer sections in the transport system permit continuous operation, even during breaks and rest periods. To ensure absolute safety of the personnel, all hazardous areas around the shot blast machine are equipped with safety mats instead of the usual sensors and enclosures.
Kevin Biller kbiller@chemquest.com
With this issue, the Ask Joe Powder column, which has been featured in the pages of our magazine since January 2022, comes to a close. The idea behind the creation of this space in 2004 stemmed from Kevin Biller, also known as Joe Powder, and his desire to provide manufacturers and professionals in the powder coating industry with a platform for useful discussions to help solve the daily challenges of this complex application. Now that this chapter is ending, we would like to thank Joe Powder for the valuable contribution he has offered to our industry over all these years.
Hi Joe,
I’m a finishing engineer at a fabrication shop and have a question regarding powder coating application. What will I notice if my grounding starts to fade?
Thomas Cooke
Salina, Kansas
Hey Thomas,
Thanks for the question. This is something that creeps up in a finishing system. You can run good parts for days, then you notice something isn’t right. First thought may be, is the powder bad, however before you start switching boxes of powder in an effort to fix the problem, you should examine your hangers and racks for a good ground. If the ground to earth is fading or inconsistent, you will begin noticing a few things. Your booth will appear cloudier, and more powder will
accumulate on the interior walls and floor of the powder booth. You may see powder drifting out the booth openings. As for your parts, you will probably observe lower film build and less penetration into corners. Powder coatings are deposited on conductive parts with an electrostatic process. The powder/air mixture is pneumatically propelled from the fluidized hopper by a venturi process and conveyed through the hoses to the gun. A negative electric charge is generated by a corona and discharged at the exit of the gun creating an electrostatic field. The powder passes through this field and picks up this negative charge. The negatively charged particles seek the nearest ground, which should be your parts.
Continuity to ground can be tested. Checking for ground to earth requires a megohmmeter which not only measures resistance but also provides up to 500 VDC which helps define resistance more accurately. 1.0 megohm
or less resistance is required for adequate grounding. Megohmmeters can be purchased online.
If you suspect poor continuity, the first places to inspect are hooks and hangers. Are the hooks coated and devoid of good, clean contact points? Hooks should be cleaned regularly and/or replaced to ensure good contact with the ground.
Well-grounded parts will have excellent continuity to the hooks/hangers which need to be connected to a secure ground to earth. This requires good contact from the parts to clean (uncoated) contact points on the hooks. The hooks/hangers should be in contact with a conductive rod buried in the earth. Ideally, this grounding rod should be about 20 mm in diameter and about 2.5 meters long. You can find UL-listed, copperplated grounding rods online or at your local hardware store. The grounding rod should be buried leaving about 15 centimetres of rod above ground for attaching ground wire(s). Getting the rod buried is a task in and of itself. Drill a suitably sized hole in the concrete, then pound the length of the rod into the earth with a sledgehammer while standing on a ladder. Not a fun endeavour. Alternatively, you can invest in a ground rod rotary bit and drill the hole using a hammer drill. My frugal self has done the sledgehammer routine. Trust me, it’s a workout.
I hope that this helps you in your quest to confirm that your finishing system has an adequate ground and that your powder coatings are applying well.
Best regards,
Joe
Dear Joe,
BITS... the most common complaint of powder coating? What are the sources of “bits” in powder and how to eliminate or control them either during the production process or during application? Please discuss.
Shafiullah Khan
Lahore, Pakistan
Dear Shafiullah,
Indeed, this is the bane of any powder producer or applicator. These defects arise seemingly out of nowhere and drive coating technologists crazy until the issue either disappears or is resolved. Simply defined, “bits” are objectionable protrusions in a powder coating film. They appear late in the game usually after the coating has cured and emerged from the oven. By then it is too late to remedy them and may require costly reprocessing and/or the scrapping of parts. Bits can emanate from various sources during powder manufacture, application and curing. Here are the most common sources of bits:
Unclean raw materials - gel particles in resins, large particle filler pigments, agglomerates in additives (flow agents especially). It is important to choose raw materials from reputable suppliers who have well managed quality programs.
Free flow (dry-blend) additives - These will cause bits if not deagglomerated during incorporation into a powder. Dry-blend additives are added to powder coatings to improve fluidization and transport performance. These additives consist of relatively large agglomerates and require intense blending to break up particle clusters.
Gel particles created in the extruder. Worn-out extruders can entrap powder material and essentially cure the product during compounding. This gelled material eventually breaks loose and becomes entrained in the powder causing unmeltable bits in the final powder coating.
Purge compound left in the extruder. Extruders are typically cleaned by passing a high molecular weight thermoplastic resin through it between product changes. If the purge compound is not completely cleared from the extruder it can contaminate the next product.
Lint from wiping rags. Low-quality wiping rages can fray and add fibres to powder processing equipment.
Environmental dirt encountered in powder production due to poor housekeeping, dirty containers, torn boxes/bags.
Dirty compressed air lines - steel compressed air lines (especially “black pipe”) can corrode and send rust particles into the application air. Air filters can help minimize this problem however eliminating the potential at the source is a much better strategy.
Environmental dirt from ovens. Baked-on residues can come loose. These bits reside on top of the coating surface.
Dirty substrates - weld spatter, environmental dirt. These are represented as “buried” particles.
Dirty racks and hooks.
A simple magnifier of 6X to 10X can tell you volumes about the nature of a “bit” The qualities to observe are size, colour, and shape. Lint is easiest to discern as it is typically observed as a coiled filament. Irregular brown or yellowish lumps are usually charred resin or powder coating binder. Suspected ferrous particles can be extracted with a fine probe and tested for magnetism. Light coloured nodular defects are usually free flow additive agglomerates or large particle size fillers. If optical analysis is unsuccessful the defects can be analysed with electron microscopy coupled with emission spectroscopy. This can determine elemental composition which usually is successful with identifying the defect causing culprit.
Kind regards,
Joe
Gabriele Lazzari ipcm®
Axelent has recently launched a new in-house automated powder coating plant designed by Moldow, that leverages the hanging systems from HangOn and the cutting-edge application technologies of Gema. Running on green energy sources such as thermal, wind and solar power, it has also allowed the Swedish manufacturer to increase production, improve paint coverage and enhance the final product quality.
In the ever-expanding world of industry and production, there are companies that manage to stand out not only for their products and services, but also for their ability to change the sector and its norms.
Axelent, a leading Swedish manufacturer known for its mesh walls for machine guarding, warehouse automation products, and recently developed crash barriers, represents a reference for this market not only for the quality of the solutions that it delivers to its customers, but also for the constant investments in production optimisation and sustainability.
As a matter of fact, it has recently launched its in-house powder coating plant, developed by Moldow as the result of a strategic collaboration with HangOn for its hanging systems and Gema for its powder coating application technologies. The new line immediately demonstrated to be successful, allowing the company to increase the production output, improve the coverage, optimise the energy use, and enhance the overall final quality of the products.
Axelent’s journey began in 1990, from three brothers and a cousin with a shared goal: to become a global supplier right from the beginning.
As a matter of fact, the company has grown exponentially ever since. In 2001, Stefan and Johan Axelsson, alongside with Mats Hilding, took over management. At that time, the company had a turnover of about €5 million and was already operating in ten countries. However, it also began to further expand outside Europe, developing its activities in the United States of America and in Asia.
Nowadays, Axelent boasts a €120 million turnover and operates in over sixty countries all around the world, with subsidiaries in Europe and the U.S.A. and warehouses in Thailand, Japan, and Australia. All production activities, however, are still concentrated in Hillerstorp (Sweden), within a manufacturing cluster that fosters cooperation and innovation among local businesses.
Production 100% made in Sweden, from raw materials to powder coating and assembly
“Although we are considering establishing a production facility in the U.S.A., in order to better serve the expanding North American market, all our manufacturing operations are currently based in Sweden, where we produce mesh walls and panels for machine guarding and warehouse automation solutions like anti-collapse shelving and pallet racks (which
account for 70% of the production), as well as a local Scandinavian product called storeroom (i.e.: a special storage required by law in Swedish apartments, where people can store their winter and summer equipment). Furthermore, the company recently ventured into producing crash barriers, made from extruded plastics, for the protection of bollards and walkways,” explains Stefan Axelsson, Axelent’s Global Account Executive. Axelent produces more than one million mesh panels each year with a single shift, thanks to five lines dedicated to the fabrication of several components with stateof-the-art machinery for cutting, forming and bending the raw materials, such as steel coils and sheets. However, the forecasts predict that the company will soon increase its shifts, in order to satisfy the rapidly-growing demands.
“Our manufacturing operations and mainly dedicated to the mesh panels, which are our core product, with dimensions ranging from 250 to 2,500 millimetres,” adds Johan Axelsson, the Technical Manager of Axelent. “Although some smaller parts like square and rectangular tubes and wires are manufactured by local sub-suppliers that are located nearby – with the maximum distance being seventy kilometres – all the other operations are carried out in-house, including powder coating and assembly of the final goods with locks and electrical wires, ready to be shipped to customers worldwide.”
1
The new customised in-house coating department developed by Moldow
Axelent previously relied on the external job coater Leba AB1 for its coating needs, but the company’s growing volume and the need for sustainability and efficiency led to the decision to develop an inhouse coatings department. So, it requested Moldow to design a new fully-automatic powder coating plant that could combine application efficiency and finish quality with reduced energy consumption and environmental sustainability.
The new coating line features an overhead monorail conveyor divided into two parallel tracks, A and B, that can run independently of each other with a speed of 4 metres per minute. It has been specifically designed to ensure the future automation of the loading and unloading operations: as a matter of fact, the Axelent staff manually hangs the workpieces on the frames provided by HangOn, but the company aims to automate also this procedure. Currently, the coating process of Axelent requires both tracks to proceed parallelly into the seven-
stage chemical pre-treatment spray tunnel, including two degreasing steps, two rinsing steps with tap water and one with demineralised water, followed by a nanotechnological conversion with Chemetall’s Oxsilan technology – succeeded by a final DI rinse. Once the items have been cleaned, they enter an electrically-heated drying oven, followed by a cooling zone. Here, the substrate of the metal parts is ready for the application of the industrial polyester powder coatings supplied by Axalta Coating System. The conveyor then splits into two separate tracks, each equipped with a pre-touchup robot, a Gema booth and a 20 m long preheating tunnel for gelling the powders, in order to avoid cross-contamination. The conveyor then reunites its two rings and leads the frames into the curing oven (that is also electrically-heated). After the cooling phase, the components are unloaded from the conveyor and moved towards the assembly line.
Increasing hanging density without sacrificing efficiency
HangOn, a Swedish developer of hanging, masking, and handling solutions, plays a pivotal role in Axelent’s coating efficiency. Its innovative
hanging systems allow companies to maximise line density, reducing energy consumption and boosting sustainability.
“By increasing hanging density, the company is able cut energy consumption by up to 50%,” highlights Andreas Orre, the Commercial Manager of HangOn AB. “We have a number of products in stock that Axelent can requested and immediately use, without having to assemble anything. In addition, since the company will soon leverage robots –developed by its robotic division, that is located in a building nearby – we are jointly studying new solutions that could further facilitate the hanging operations and improve its density, without compromising the efficiency of the pretreatment or the application phases.”
coverage on all corners and geometries
Axelent’s new coating plant leverages the state-of-the-art application technologies provided by Gema. It features two MagicCompact
EquiFlow BA04 booths with cyclone technology, equipped with two reciprocators each with ten OptiGun GA03 automatic spray guns per side. These booths are designed for quick colour change, with each
booth dedicated to one colour (black or grey), while special colours are still applied by Leba. The coating process begins with two pre-touchup robots equipped with Gema guns to ensure complete corner coverage, followed by the automatic application of Axalta’s industrial polyester powder coatings. Gema’s MagicControl 4.0 system control, equipped with the GemaConnect Dashboard, manages the entire process, offering an intuitive interface for operators to create standardised programmes and adjust film thickness as needed. “Finally, the OptiSpray AP01 dense-phase technology application pumps and the OptiCenter OC07 for excellent coating quality and fast colour change also brought us three advantages right from the outset: increased powder penetration, improved film distension, and reduced powder consumption,” clarifies Stefan Axelsson.
Immediate results: flexibility, consistency, reliability, and sustainability
Axelent started its powder coating operations at the beginning of April 2024. After an initial testing phase, during which the operators learned
how to precisely perform all the related tasks, the coating plant is now fully operational and allows the company to achieve a more accurate powder application that ensures a more performing and aesthetically-appealing finish, besides sustainable and economic advantages as well.
“We were very satisfied with Leba’s quality and its services. As a matter of fact, we still collaborate with this job coater for special colours and effects. But two lorries full of our products went back and forth daily. Since carbon reduction is one of our main goals, we wanted to find an alternative,” continues Stefan Axelsson. “So, also in order to optimise production flow, we then decided to bring the coating operations in-house”.
The coating facility runs in fact entirely on green energy, sourced from a geothermal system and solar panels installed on the factory’s roof. Additionally, Axelent has invested in windmills, producing all the electricity needed for its operations. The company also employs five heat pumps that recover thermal energy to heat up the pretreatment water and cool down the cooling areas of the plant, as well as the whole production department.
“We try to keep as much energy as possible within the system,” says Johan Axelsson. “It’s a combination of green energy technologies, and we even have our own wastewater treatment plant with vacuum evaporators that eliminates the need for chemicalphysical treatment, removing the sludges and recovering the entirety of the water in a closed loop circuit.”
“The entire process, from the initial meeting with the plant developers from Moldow to the final handover with the technicians from all the partners involved, has been characterised by a very smooth cooperation between everyone. For example, during the planning stage we considered opting for a Power&Free conveyor. But the solution proposed by Moldow ensures us to reach the exact level of customisation and flexibility that we need for our coating process. The new powder coating plant is a shining example of the results that it is possible to achieve by combining efficiency, flexibility and sustainability: we have increased the production output, optimised energy use, and enhanced the quality of our products”, concludes Stefan Axelsson.
From top:
The OptiCenter OC07 powder centre. Coated workpieces exiting the curing oven.
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By the editorial team
"Excellent firms don’t believe in excellence – only in constant improvement and constant change." Tom Peters
The search for plant solutions that increase energy efficiency while reducing consumption without compromising on performance is the order of the day in industrial coating departments. In particular, gas, the cost of which has risen sharply in recent months, is the energy source on which all industry players are now focusing their attention, as it is used in the combustion chambers of heat exchangers to heat the radiant sections generating the hot air required for drying, polymerising, or curing in industrial coating processes.
Apen Group SpA is an Italian company that has been manufacturing heating systems for almost sixty years, offering a wide range of products from condensing boilers to wall-hung and floor-standing hot air generators. Founded in Milan in 1967 by two visionary brothers-in-law who coincidentally bore the same name, Angelo Rigamonti, its history is inextricably linked to the economic and social evolutions brought by this indispensable energy resource during the Italian and global post-war industrial development. Over the years, this company has mainly specialised in designing and manufacturing (condensing and non-condensing) heat exchangers for a variety of industrial processes requiring hot air, such as food, ceramic, and textile drying systems, agricultural, grain, and tobacco drying plants, or drying, ventilation, and polymerising and/or curing ovens in our industry. “Today, Apen Group also has a strong presence at the international level while remaining
a family-run business to guarantee consistency in the definition of company policies and rapid decision-making. It has long identified its mission in the continuous search for solutions to optimise the use of natural resources and in the definition of preventive and corrective controls to comply with quality and sustainability objectives by raising awareness of employees, suppliers, and partners on these issues,” explains Paolo Rigamonti, President of Apen Group SpA.
“We consider caring for the environment – understood in a broad sense in terms of people, relationships, and cooperation – our path to excellence,” says Christian Mancini, the Export Sales Manager of Apen Group SpA. “Significant investments in research and development aimed at designing and constructing energy-efficient systems enable us to guarantee reliable products, energy-saving advantages, and low maintenance costs to our industrial partners.”
materials, efficiency, and design: the foundations for sustainability
The Apen Group team has been implementing several strategies to pursue the path of sustainability, starting with the design of its heat exchangers. “The layout of a heat exchanger can determine an entire thermal process: since this system is its main component, it is crucial to adopt the best solution based on the line’s design and technical and
installation characteristics, beginning with the choice of materials,” adds Mancini. “Thanks to its long-standing experience, our R&D department has identified some stainless steels, such as AISI 441 and AISI 310, able to guarantee a long service life and a low level of wear caused by temperatures and high heat transmissibility. Moreover, because they are made entirely of stainless steel, our heat exchangers can be 100% recycled or disposed of. Specifically, in standard projects, they are made of AISI 441 steel, whereas we recommend opting for AISI 310 steel when the maximum flow temperature exceeds 125 °C and the temperature difference between the heat exchanger’s inlet and outlet is greater than 115 °C.”
From home to factory: the all-round experience of Apen Group
The heat exchangers manufactured and distributed worldwide by Apen Group are also used in air conditioning systems for commercial
use, such as air handling units – a sector strongly affected by efficiency, environmental protection, and gas consumption-related regulations. “It is the same technology applied to industrial processes. It guarantees high-performance and efficient systems: under heating conditions with an airflow rate of ∆T of 35 °C and an inlet air temperature of 15 °C, the efficiency of a single heat exchanger can be more than 102%. Indeed, to meet the numerous demands and requirements of international markets, over the years, our R&D department has developed multiple heat exchangers that have an efficiency rate exceeding 100% while always meeting the heat demand through the correct combination of fan and burner sections (of on/off, two-stage, or modulating types).”
Another critical element in reducing gas consumption and, therefore, the cost of the plant for the thermal process is the specific layout and configuration of the heat exchanger. Consisting of a combustion chamber and a tube bundle, this system’s particular shape ensures a
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high aerodynamicity and thus reduced friction of the airflow, which runs over the entire exchanger thanks to its peculiar geometry and large contact surface area, maximising its operation.”
The most common solution offered by Apen Group for industrial processes is its G0 series, which includes 9 different types of heat exchangers with an output power ranging from 50 to 550 kW, resulting in a total of 33 models depending on their construction characteristics. The G0 series’ combustion chambers are designed to be fitted in hot air generators operating with gas and diesel oil burners (the latter only available on request) and air handling units. The company’s long experience in the research and development of heat exchangers has led to the registration of no less than three notable patents.
“The standard series (G0xxxx),” Mancini indicates, “includes basic models conceived and designed for installation in plants operating under standard conditions, that is, typical of air handling units, with not too high temperature differentials and sufficiently high air flow rates (∆T between 20 and 35 °C). The G0xxxx-2 and G0xxxx-310 series, on the other hand, are designed to work under special operating conditions, such as in process plants, in coating and drying chambers, or at high static air pressures. Specifically, the G0xxxx-2 heat exchangers can withstand high pressures (up to 2,500 Pa) as they are made of highly stress-resistant materials, whereas the G0xxxx-310 ones can operate at very high air temperatures (up to 280 °C) or with high air temperature differentials thanks to the special materials they are made of.”
GH and EMS series heat exchangers
The difference between the GH and EMS models lies in their intended use. “The GH modules,” explains Mancini, “designed to be integrated into air handling units, have
a lightweight galvanised sheet metal frame that allows inserting them inside dedicated structures. The EMS modules, on the other hand, conceived to be directly ducted or placed in series with air handling units, have a structure consisting of an aluminium frame and sandwich panels insulated with rock wool, in white pre-painted sheet metal (external surface) and galvanised sheet metal (internal surface).
“In all of these series, the combustion chamber and flue gas collectors are made entirely of stainless steel, while the surfaces in contact with the flue gas (tube bundle) are in lowcarbon stainless steel to ensure high corrosion resistance. Our tube bundle’s design is patentprotected.”
The flexibility of heat exchangers depending on the applications
Heat exchangers can be inserted into air heating units in either a vertical or a horizontal position. “The airflow can be of two types: equicurrent, when cold air first hits the hottest part of the exchanger, i.e. the combustion chamber, and countercurrent, when cold air first hits the coldest part of the exchanger, i.e. the tube bundle. Depending on the application, one or the other installation mode may be more convenient. In addition, to achieve the degree of performance demanded by specific applications where the required thermal power exceeds the maximum available power of a single heat exchanger or where the minimum thermal power is to be reduced below the minimum value of a single heat exchanger, it is possible to assemble several heat exchangers in one ventilation and/or process system reaching high thermal power levels. With appropriate precautions, the modules can be assembled either in series or in parallel.”
Thanks to constant product and process innovation and the continuous search for advanced technological solutions to offer unique, high-quality products that are always
up-to-date and in line with the actual needs of international markets, Apen Group has always been a company at the forefront of the industry. “In addition to these advantages,” Mancini concludes, “our sales and technical staff also offer excellent service in both the pre-sales and after-sales phases – an aspect to which we have paid great attention since the beginning, to fully support our partners that have chosen to rely on an Italian-made product complying with high-quality and certification standards.”
Monica Fumagalli ipcm®
On the occasion of the replacement of the MB-339 aircraft with the new MB-346, the Frecce Tricolori changed their livery and abandoned Savoy blue in favour of an elegant combination of dark blue and white, designed by Pininfarina.
When they dart through the clouds at unimaginable speeds, painting the sky with their contrails in the colours of the Italian flag, they leave everyone breathless: the Frecce Tricolori, the aerobatic demonstration team of the Italian Air Force, captivate the imagination with the incredible precision of their performances carried out at astonishing speeds. These ten jets can reach a maximum speed of almost 900 km/h with stress rates that, in the case of the solo pilot, i.e. the one detaching from the formation to create impressive figures in perfect coordination with the other nine, reach a positive gravity acceleration of 7.5 G – that is like being “crushed” by a weight of 750 kg for a person weighing 100 kg.
Italy’s Frecce Tricolori were conceived with their current characteristics in 1961. They are the world’s most numerous aerobatic patrol and the only one that can perform shows with a formation of ten jets drawing a five-kilometre-long tricolour in the sky. That is why they are recognised as one of the best aerobatic patrols internationally.
In September this year, during the ceremony celebrating the return of the Frecce from the North America Tour 24, it was announced that the Aermacchi MB-339-type aircraft currently used by the patrol would be replaced with the new MB-346 model built by Leonardo Spa, the Italian public-controlled company active in the defence, aerospace, and security sectors. Adapted to the specific needs of the aerobatic demonstration team, the new planes also sport a new livery designed by Pininfarina.
The fuselage of the MB-339, the aircraft that has served this aerobatic patrol for over forty years, features a predominant Savoy blue colour in its most recent version, with the Italian tricolour running from nose to tail on both sides. On the tail, together with the colours of the Italian flag, the number of each jet’s position in the formation is depicted in Savoy blue. The back of the wings is the same colour as the fuselage, interrupted by white bands running along each wing. The jet’s belly is painted silver.
The place designated for painting the Frecce Tricolori’s aeroplanes is the coating booth installed in the hangar of the 313th Aerobatic Training Group, in the northern area of the Rivolto Air Base (Udine). Here, the Frecce Tricolori’s maintenance personnel makes sure that every detail is perfect: behind the scenes of this patrol’s stunts is a perfectly synchronised team (just like the one flying in the sky) who guarantees the safety, functionality, and even the aesthetics of these very special and complex vehicles.
The liquid paints creating the iconic livery are applied manually by specialised operators in a custom-built booth, designed exclusively for this operation and adapted to the shape of the plane to be coated without the need to dismantle any components. “The booth follows the profile of the aircraft exactly so that it can be moved easily and features a series of tailor-made doors,” says the technical team of Blowtherm Spa, the company commissioned by the Air Force to oversee the booth’s
project. “Airflow and temperature are homogeneous over the entire aircraft surface, thanks to powerful industrial fan units that also ensure optimised consumption. The control panel of the thermal ventilation unit ensures excellent temperature control and airflow efficiency.”1
“A new era begins for the Frecce Tricolori,” states Pininfarina’s press release, “an internationally recognised symbol of excellence from the Italian Air Force, which will soon be equipped with the M-346 aircraft, a jewel of Italian industry created by Leonardo, tailored to the specific needs of the National Aerobatic Team. Enhancing the iconic status of this new star of the air shows is the livery, designed by Pininfarina’s designers, yet another ambassador of Italian excellence. With this collaboration, three symbols of ‘Made in Italy’ come together to carry the Italian Tricolore across the skies of the world.”
The new livery – with the fuselage and wings coated in the predominant tone of dark blue, combined with the national flag’s colours emphasising the underside outline and white surrounding the cockpit – represents the beauty and fluidity of the Frecce Tricolori’s flight. “The result is a three-
1 https://www.blowtherm.it/en/realizzazioni/paint-system-foraircraft/
dimensional design that ensures, during the aircraft’s manoeuvres, a recognisable graphic element is always visible, conveying a sense of speed and dynamism to the audience. It is a perfect combination of elegance and power, traits that are characteristic of both Pininfarina and the National Aerobatic Team, embodying hard work, ingenuity, and teamwork, the core values of the Italian Air Force. This synergy between Pininfarina, renowned for its innovative and refined design, and the Frecce Tricolori, which were entered into the Guinness World Records in 2022, is thus a tribute to Italian excellence.”
“It is a great honour to present the new Frecce Tricolori livery designed by Pininfarina,” said Silvio Angori, Vice Chairman and CEO of Pininfarina. “This project is inspired by what we have defined as the Renaissance of the Tricolore, an idea that embodies our national pride and celebrates the symbol that represents us around the world. The Frecce Tricolori are not only an emblem of technical skill and precision but also of passion and dedication. With this livery, we celebrate their spirit and commitment, creating a design that will accompany their breathtaking performances for decades. We thank the Italian Air Force for the trust they have placed in Pininfarina and its creativity, which for almost ninetyfive years has continued to represent Italian design worldwide.”
Maximum efficiency in using energy resources and coating products, premium coating quality in terms of parameters such as coverage, film distension, thickness uniformity, and finish, but also increased coating capacity and reduced assembly lead time. These were the objectives specified and achieved by Comel with its project for a new automatic powder coating plant integrated with its internal assembly logistics, which involved Futura, Imel, Wagner, Lesta, and Chemetall.
The development horizon of the contract coating industry is increasingly projected towards the vertical integration of processes and services to complement coating. Focussing on quality, implementing lean production practices to streamline production and shorten delivery times, and complying with international quality standards are all tools that the most professional contract coaters use to remain competitive and, at the same time, counter the trend that is seeing many manufacturing companies insource their coating operations.
By integrating surface treatments with new processes, the largest and most structured companies can become full-fledged external production departments for their customers, managing a number of production steps beyond finishing, including quality and conformity controls. At the same time, today, a coating contractor should provide measurable technical performance in line with the current requirements related to environmental, social, and economic sustainability. This is the path undertaken by Comel SpA (Arre, Padua, Italy), already the protagonist of an extensive report on ipcm® in 2015 after installing its first state-of-the-art automatic coating system to replace the two plants used until 20131. Thanks to a solid financial and industrial base and aiming to constantly increase process efficiency and profitability, Comel today offers a comprehensive, fast, flexible, and high-quality service to its loyal customers, of which it is often the exclusive contractor. Propensity to innovate, investment in advanced technology, and staff training also play a key role. In October, we returned to Comel to visit what is one of the largest in-house handling and coating plants operating in Italy today, built in 2024 in collaboration with a pool of suppliers specially chosen to bring in their best technologies and meet the company’s primary objective: increasing its powder coating production capacity while optimising its process flow by linking its two main operating phases, i.e. finishing and assembly, thus reducing waste.
1 A. Venturi, High Energy Efficiency And Productivity For Comel’s Coating Plant, in ipcm® no. 31 Vol. VI, January-February 2015, pp. 84-92
For this impressive project, Comel relied on the skills and experience of Futura (Robecco Pavese, Pavia, Italy), Imel (Codroipo, Udine, Italy), Wagner (Valmadrera, Lecco, Italy), Lesta (Dairago, Milan, Italy), and the Italian division of Chemetall (Giussano, Monza e Brianza, Italy), which collaborated for almost two years to realise the ambitious goals of this company.
Founded by Luigino Giacometti in 1970 as a sheet metal, stainless steel, and aluminium treatment contractor exclusively for the air conditioning sector, Comel opened up to other industries in 2000. Since then, the composition of its turnover has diversified considerably. Its technical department provides constant support to customers not only for new projects or the industrialisation of existing ones but also in searching for alternative technical solutions to increase competitiveness. What sets Comel apart from its competitors is the comprehensiveness of its service, which ranges from cutting, bending, and welding to coating, assembly, and kitting.
“We have grown, improved, and transformed significantly over the past ten years. We constantly assess the best technologies on the market, and we rely heavily on our human resources when it comes to technical
skills. In our coating department, some key roles have changed: since 2016, we have had a process optimisation manager, Nicola Cesarato, to support our management in the required investments and in the transition to a sustainable future. His role in the design of our new coating plant was crucial,” states Matteo Giacometti, technical sales engineer at Comel and one of the founder’s sons.
“Like many other contractors, we saw a surge in volumes in 2021.
Until then, the existing coating plant had been sufficient to meet our needs, although we had begun to rely increasingly on a subcontractor for work peaks and for handling special colours in small batches. That year, however, we realised that working on two shifts, we had saturated the plant’s capacity. As we did not intend to introduce a third shift and realised that an increasing number of parts to be coated also required assembly, we decided to improve our coating production capacity and create a more automatic and efficient workflow by linking surface treatment to assembly,” Giacometti explains.
“Our objectives were to be more independent, increase our finishing quality and response speed, and equip ourselves with a back-up coating system. Although, in ten years, the existing plant had never had any problem that kept it down for more than 24 hours, we felt it was our responsibility to eliminate any risk of downtime that would lead us
to run out of stock and stop production, since volumes were increasing as were our customers’ expectations in terms of speed, flexibility, and quality of service. High-turnover workpieces requiring both coating and assembly now account for 35% of our activity. We knew that combining these two operational phases in a single workflow managed by one conveyor would have allowed us to streamline the handling of a very high quantity of parts, eliminating the risk of damage and reducing lead times, as well as to assign some operators to other tasks.”
“For this project, we turned to Futura for the design of the handling system, the logistical organisation, and the feeding of the assembly stations: we felt it was the only partner able to provide us with adequate and reliable solutions. We then chose to keep Chemetall as our pre-treatment chemical supplier: this way, we could use the same products in both our plants and achieve comparable quality results. Chemetall, in turn, collaborated with Imel, our selected partner to build the coating line and develop a pre-treatment cycle with the same number of stages as the previous one but with a higher degree of quality,” says Matteo Giacometti. “We chose Imel because, besides its know-how and the possibility of implementing its i4paintshop advanced management module, we trust it can provide us with a constant and reliable assistance service.
“Finally, Wagner’s IPS technology was a natural choice: we immediately asked the companies involved to enable us to paint parts with minimal human intervention, i.e. as much as possible with automatic reciprocators and without using systems to adjust the distance from the components via independent axes, and to achieve the best possible coverage. After several trials with test workpieces, the IPS technology was the only one to reach these results, minimising
human intervention in all coating phases, from pre-finishing to colour change: the production rhythm is defined by recipes and programmes. This was exactly the same philosophy we demanded from the conveyor. Finally, we decided to install 2 articulated robots from Lesta with a 3D imaging scanning system to assist with pre-finishing operations. We have only equipped one of the 2 booths for now, but we intend to do the same on the other.”
Conveyor design: seamlessly joining two production stages
“We illustrated to Futura our requirements, the operating stations we considered necessary on the conveyor route, and the results of a preliminary study on workloads, assembly times, and positions,” says Nicola Cesarato.
“We then adapted and modified their proposed solutions by conducting industrial simulations to ensure we could achieve the perfect balance between coating, assembly, and handling times, as well as between the necessary storage buffer’s size and assembly times. A highly productive coating line with bottlenecks during unloading or assembly would not have served our efficiency objective. I personally noted the assembly times of the main components that would be hung on the conveyor, and we reverse-engineered all the other processing times based on them.”
“This study led us to identify the number of parts to be handled per hour and, as a result, the characteristics of the line. In other words, cycle times were the starting point for developing this conveyor,” notes Paolo Chiesa, project manager at Futura Srl.
From the top:
A detail of the Futura power & free conveyor’s complex turnout system.
One of the buffers included in the conveyor route, specifically the one in front of coating booth #1, which applies light colours.
“Compared to our ‘typical’ systems, Comel’s conveyor has the peculiarity of integrating a coating line with an assembly one. That is why it features storage buffers feeding several unloading lines near which other activities are carried out.
“It is a power & free conveyor with a maximum capacity of 200 kg per load bar, each of which is 4 metres long, a throughput of 44 load bars per hour, and a chain length of just over 3 km. The line speed is 3.5 m/min, and the takt time is 82 seconds. The conveyor is built on two storeys to double its functions and features two types of storage buffers: on the lower storey, it takes the components along the coating line and has 1 storage buffer before the pre-treatment tunnel, 2 in front of the coating booths, and 1 after the curing oven; on the upper storey, it serves the warehouse for coated parts and empty load bars.”
“After the coating plant, the conveyor branches into two routes: one leads directly to an unloading station, the other takes the parts to the upper storey, where 8 storage buffers for coated parts are ready to feed 4 unloading and assembly stations below them. The conveyor’s PLC then recalls the load bars containing the workpieces to be assembled according to the daily production plan: each load bar thus leaves the warehouse and reaches the assembly area automatically.
In total, the plant handles 370 load bars, 300 of which can be accommodated by the second-storey warehouse.”
“In the coating area, there are 2 continuous-flow loading bays, where the load bars initially move on a low height to enable the operators to hang the parts first at the top, which is at eye level; the conveyor then creates a vertical curve that allows the load bars to move up by 1.40 m so that the operators can load the parts at the bottom of the unit, ensuring excellent work ergonomics without the need for elevators,” explains Futura’s owner, Alessandro Longo. “In practice, the operator always finds the empty position for hanging the next workpiece at eye level. This was a specific request from Comel, which did not want to employ elevators during loading so that the plant itself could dictate the operating times: with this solution designed by Futura, the loading times are pre-set by the coating recipes matched to the individual load bars and are updated based on the operators’ recommendations, creating common working standards.”
“Each load bar has an ‘identity card’ that defines its route along the line, loading speed, pre-treatment cycle, blow-off power before drying, and powder application recipe,” confirms Matteo Giacometti.
“Another optional value attributable to the load bars is quality control,”
adds Nicola Cesarato. “If it is set, after coating and on leaving the oven, the load bar will stop to undergo an operator check. For example, we do this for the first load bar coated with a new colour or carrying a critical component, as well as with a certain frequency for specific production batches.”
“From the mechanical point of view, Futura has fitted the conveyor with another technology that is very useful in the pre-treatment phase,” indicates Alessandro Longo. “The load bars can tilt while in motion without stopping to be repositioned horizontally. This mechanical movement eliminates any liquid build-up formed within the parts during the pre-treatment cycle, thus facilitating the subsequent blow-off and drying phases and minimising the drag effect from one tank to the next.”
The powder coating plant. Efficient and aesthetically appealing
“The coating line supplied to Comel includes a stainless steel spray pre-treatment tunnel that performs a 7-stage multi-metal cycle, including double alkaline degreasing, double rinsing with distilled water, rinsing with demineralised water, nanotechnology conversion with Chemetall’s Oxsilan, and further rinsing with demineralised water,” says Marco D’Angela, the owner of Imel. “The pre-treatment tunnel is U-shaped, with 4 tanks on the left side and 3 tanks on the right side: this design solution allowed it to fit within the dimensional limits of the building that was to house the line. It is followed by a continuous-flow blowoff station that avoids any liquid build-up in undercuts before the drying phase in a hot-air oven. After drying, the parts follow a cooling path and then stop at 2 storage buffers, each feeding one of the 2 Wagner application booths. Both booths are housed in air-conditioned, temperature-controlled, dust-free, and humidity-controlled boxes. They work simultaneously: one applies light colours and the other dark ones.”
“The biggest design problem Imel faced was avoiding mutual contamination between parts coated in different colours within the humpback curing oven,” says D’Angela. “That is why we created a hot-air gelling pre-chamber. The special feature of the drying and curing ovens, both with a combustion chamber and a gas burner, is that they are superimposed: the lower part is for drying, the upper part for curing. This results in considerable energy savings. Finally, we also paid great attention to the aesthetics of this plant and the colour of its metal parts – yet another high-quality choice for Comel.”
After curing, the load bars with the coated parts reach the area where the conveyor branches off: one route leads to a direct unloading station, the other the upper storey’s warehouse from where the load bars are then recalled according to the production schedule, descending to the 4 unloading stations dedicated to assembly operations. All 5 unloading stations are equipped with lowerators.
“The surface treatment process also includes the possibility of retaking
the load bars in the coating booths for the application of a second layer of powder, which is increasingly required by our customers”, Matteo Giacometti points out.
“Imel’s i4paintshop module for plant management and predictive maintenance is another plus in this project. This module and the conveyor and booth management software programs are highly integrated with each other and with our company’s management system, where all treatment recipes are recorded. Every load bar sends back information at the end of each cycle, so we know exactly the process times, all operating parameters, and any alarms caused by problems during processing.”
“There are three reading points for the barcodes on the load bars, located in three strategic areas within the plant: the entrance to the pre-treatment tunnel, the quality control area, and the entrance to the assembly area,” explains Paolo Chiesa from Futura. “Thanks to them, the conveyor’s management system knows which load bar is passing
The 2 robots incorporate Lesta’s Image Match 3D scanning system. Each reciprocator in the booths is equipped with 8 automatic guns.
The booth applying dark colours still has 2 manual pre-finishing stations, but it is already prepared for robotic automation.
through any given point and at any given moment: this information is essential, also for recalling the bars to the assembly stations. The conveyor’s PLC collects and distributes all this data to Comel’s company management system, Wagner’s PLC, and Imel’s i4paintshop module.”
“At Comel, Wagner has installed 2 Supercube booths with 2 IPS powder feeding systems,” says Marco Spada, the Area Manager-Powder Coating of Wagner SpA. “When a load bar arrives, the booth recognises the application recipe matched with it and performs the programme automatically. The IPS system – which has no wearing parts except for one component of the electrostatic feeder – guarantees powder delivery with consistent parameters for each coating recipe over time, for at least 2,500 working hours.
“One of its advantages is that it ensures remarkable penetration and uniformity even in the absence of 3D part recognition devices because
it has the Dual Zone system, which enables it to change the flow rates of the nozzles simultaneously in a fraction of a second, thus increasing the amount of powder dispensed and the air speed used when covering the deepest surfaces and decreasing the powder output kinetics on flat surfaces, to obtain uniform thicknesses on both flat and concave areas. Comel, in particular, can exploit 90% of the IPS system’s potential, as it coats parts with sometimes very complex geometries, controls coating thicknesses, and has high quality requirements. On box-type profiles with a depth of 600 mm, for example, it only needs to pre-finish a few inner edges, while covering the outside, inside, and bottom with minimal pre-finishing requirements.”
The 2 coating booths are identical. However, one is equipped with 2 Lesta articulated robots for pre-finishing, installed on the same side; the other has 2 manual pre-finishing stations, although already prepared for the future integration of robots. As 98% of pre-finishing operations are required on the concave surfaces of parts, the robots or operators work
on the same side, although the stations allow for both right- and left-handed use.
“We installed industrial-grade, ATEX-certified Kuka robots with Image Match 3D, a scanning system we developed in recent months that recreates various points on the part to be coated by identifying the actual position of the object as it passes through the coating line. That allows adapting the pre-set pre-finishing path very precisely to the component’s actual position and its multidirectional movement in space, due to the use of different hooks than expected, for example,” explains Lesta’s owner, Emanuele Mazza. “In addition, we have recently released an update of our self-learning programming mode that allows importing the generated programme into the offline programming software package, optimising details or correcting errors, and then regenerating the file to be sent to the robot.”
“This project was a significant experience for Wagner in two respects,” Marco Spada emphasises. “The first was the high finishing quality specified by Comel, higher than that required in the household appliance industry. With some powders, we are using 140-µm sieves despite coating huge surfaces with high line speeds. Indeed, Comel’s requirements included the total absence of paint pitting, maximum penetration, uniform distribution, and thickness consistency on all surface areas.
From the top:
The ascent of the load bars in the humpback curing oven.
Load bars leaving the humpback curing oven. The gelling pre-chamber inside it allows curing load bars with parts coated in different colours without any gaps in the chain.
“The second aspect of this project that has allowed Wagner to grow a lot was the booths’ suction requirements. Having 2 prefinishing stations on the same inlet side – controlled by 2 robots or 2 operators, respectively – spraying next to each other, it was challenging to properly position the suction point where the overspray produced by this operation should be conveyed. We had initially thought of placing a suction point directly on the platform, but we would have lost the possibility of recovering the overspray generated during colour changes. Working in close cooperation with Imel, we opted for a system ensuring that overspray is sucked out of the booth and sent to the cyclone for recovery, even in the absence of a down-draft suction device at the pre-finishing stations. On the part of both Imel and Wagner, a great deal of effort was put into optimising the airflow and fluid dynamic balance within the clean rooms and booths. The design work we did with Imel has led to extraordinary results: a suction system with perfect fluid dynamics and, therefore, unrivalled coating quality and high colour-change efficiency.”
“Over the past year, we have counted 130 active colours on both plants. 5 of these account for 40% of our total production volume. This new system handles between 70 and 80 tints, with an average of 3 colour changes per day on each booth,” illustrates Nicola Cesarato.
“Our goal is to apply all colours with both plants.”
“The finishing quality that our customers have appreciated over time is the one we have to stick to: while it is true that we use many textured colours that are easier to apply, we also use numerous wrinkled, matte, or metallic colours that are much more critical.
I realise that achieving these quality standards was a challenge for the suppliers that worked on this line, particularly Wagner,” says Matteo Giacometti. “Precisely intending to maintain consistent quality, we have relied on two main suppliers of powders for many years now, AkzoNobel and Sherwin-Williams, also trying to steer any customers specifying powders of different brands towards these two providers, which specifically fine-tuned their formulations when we implemented this new plant. Indeed, for the same colour, Wagner’s IPS application technology requires powders meeting certain standards, with formulations adapted to it.”
A high degree of satisfaction and praise for the team “The plant has been in operation since January 2024. There were some initial problems, but once solved, I can say we are fully satisfied with the investment and the group of companies we chose as our partners,” states Matteo Giacometti. “By the end of the year, we should also have data on savings rates. After eight months of use, however, we are already seeing several improvements in terms of efficiency that justify the investment made and that we appreciate. Reducing waste as much as possible and making paint and energy consumption – the two main cost items of a coating line – more efficient were among our main goals with this project.”
“I would also like to applaud Comel’s operators and technicians, who have worked hard to understand this change in technology and learn to use both the booths and all other equipment to their full potential. Such
a positive and collaborative attitude was not to be taken for granted: there was a risk of bringing in operating methods that could be incorrect if applied to these new technologies.”
“We are already thinking about the future,” Giacometti concludes. “A short-term project is the further expansion of the coating plant’s direct unloading area with the addition of a second station, again in cooperation with Futura. The contract coating market evolves rapidly, and our mission is to stay ahead of the curve to always meet our customers’ needs.”
MELTING AND COMPLETE CURING of powder coating and liquid coating drying with the INFRAGAS technology
Federica Alberti, SG Projects Srl – Voghera (Italy) federica.alberti@sgprojects.it
Eric Butin, CHEMRA GmbH - Trier (Germany) e.butin@chemra.com
As a company specialised in water treatment, Chemra has found in SG Projects its trusted commercial partner in Italy to support clients in one of most challenging application, the removal process of PFAS, ‘forever chemicals’ that disperse easily and do not readily degradable contaminant.
The painting industry is continuously improving the recipes and composition of its products to meet market needs and expectations. The first patents concerning the use of PFAS in the paint industry date back to the 1960s.
These patents were filed to exploit the unique properties of PFAS, such as their resistance to water, stains, and chemicals. PTFE (polytetrafluoroethylene) was one of the first compounds in the PFAS family to be patented and used in various industrial applications,
including paints. The non-stick and chemical resistance properties of PTFE led to its adoption in coatings and paints. Later, other PFAS were introduced into paint formulations to improve durability and heat resistance. The use of PFAS in paint formulations has become indispensable due to their beneficial properties.
Per- and polyfluoroalkyl substances (PFAS) are man-made chemicals with both hydrophilic and hydrophobic properties. Due to these characteristics, they are both oil and water repellent and have been used in a wide range of products for decades. The PFAS chemical group comprises a large number of substances with varying characteristics, such as their physical properties and toxicity. Perfluorinated compounds are hydrocarbons in which all hydrogen atoms have been replaced by fluorine atoms, while polyfluorinated substances have only some of the hydrogen atoms replaced by fluorine.
In the nomenclature, the substance classes (carboxylic acid or sulfonic acid) are indicated at the end with “A” or “S”, where “A” stands for carboxylic acid and “S” for sulfonic acid. The third letter represents the chain length. For example, in PFOA, the “O” (octane) stands for the chain length of 8 carbon atoms.
We have long and short-chain PFAS. A PFAS is considered a long-chain compound when the chain length is ≥ C8 for carboxylic acids (e.g., PFOA) and ≥ C6 for sulfonic acids (e.g., PFHxS and PFOS).
Below is a representation of the structure of PFOA (Perfluorooctanoic acid) with a chain length of 8 carbons. The drawing shows the hydrophilic part and the hydrophobic part, which provide the interesting properties of this amphiphilic substance (Fig. 1).
PFAS in the paint composition have been considered for different reasons:
Water and stain resistance: PFAS make paints more resistant to water and stains, which is particularly useful for exterior surfaces and humid environments. PFOS (perfluorooctane sulfonate) was used for this purpose, but its use has been restricted to applications other than paint. To replace PFOS in paints, several alternatives are used, such as PFBS (perfluorobutane sulfonate), which is often used as a substitute due to its similar chemical structure but with a shorter chain, making it less persistent in the environment. ADONA (3H-perfluoro-3-[(3-methyl4-oxo-2-oxetanyl)oxy]propanoic acid) is also an alternative, as it is less bioaccumulative than PFOS.
Non-stick properties: PFAS give paints non-stick properties, making painted surfaces easier to clean. PFOA (perfluorooctanoic acid) was used for this purpose but is now forbidden due to its negative effects on the environment and human health. To replace PFOA with less harmful alternatives in paints, we now introduce PTFE (polytetrafluoroethylene) again. Although PTFE generates some trace amounts of PFOA during its manufacture, low PFOA or PFOA-free versions can be used. Alternatively, PVDF (polyvinylidene fluoride) can be used, as it has similar properties without the same risks associated with PFOA.
Durability and chemical resistance: PFAS increase the resistance of paints to extreme weather conditions and chemicals. PFNA (perfluorononanoic acid) is the most common PFAS used to improve this specification.
Heat resistance: PFAS improve the resistance of paints to high temperatures, which is beneficial for industrial applications. PFHxS (perfluorohexane sulfonate) is added for its heat and chemical resistance properties.
Unfortunately, PFAS have also some disadvantages. They are persistent pollutants and can have adverse effects on human health and the environment.
The selection of these substances aims to limit health risks based on current knowledge, but many toxicological and environmental studies are being conducted worldwide. As a result, formulations using PFAS may evolve in the future, and efficient and cost-effective solutions are proposed for the removal of these substances from wastewater.
Due to the very strong and short bond between carbon and fluorine, PFAS concentrations in water are not reduced by conventional treatments. Another challenge is that these substances, even at trace levels, are generally present in wastewater along with high concentrations of other contaminants, which affects the efficiency of adsorption media. The initial perfluorinated compounds were long chains and can be easily removed by activated carbon filters.
However, PFOS and PFOA have been replaced by shorter-chain PFAS, which are more difficult to remove. While activated carbon remains effective for long-chain substances (≥ C8), it has lost its competitiveness compared to ion exchange resins for short and ultra-short chains, which leak very quickly from carbon units.
Chemra GmbH is an independent chemical company established in 2010, that works in close cooperation with renowned engineering companies to find the most cost-effective solution in plant design for each customer. With this goals in mind Chemra GmbH team create in their lab an innovative product to remove PFAS.
The solution for both short and long-chain PFAS is to use specific resins.
The superior perfomances of IX resins are due to the negative charge of dissolved PFAS at neutral pH, which allows ionic bonding between the resin and the dissociated acid.
This is in addition to the Van der Waals forces that attract the hydrophobic part of the substance to the surface (external and pores) of the resin. These ionic bonds limit the release of already fixed PFAS. Specific resins for Per- and polyfluoroalkyl substances differ from standard anionic resins by having a functional group that attracts the dissociated PFAS more effectively than other anions present in water.
As a result, IX resins are highly efficient at removing both short and long-chain PFAS. On economical point, the ion exchange kinetics are fast, so an Empty Bed Contact Time (EBCT) of less than 6 minutes is sufficient, which means requiring 3 to 5 times less volume than other product available in the market. This lower volume of media also translates to lower capital expenditure (capex) for the vessels. Finally, depending on the type of PFAS, Chemra have experienced service times between 25,000 and 150,000 Bed Volumes (BV). Longer operating capacity and higher quality of treated water are achieved thanks to a lead-lag layout: the lead column operates above the threshold limit, optimizing operating capacity, while the lag column provides the polishing step for the best quality of treated water (Fig. 2).
Wastewater may also contain organic matter (COD) which can affect the operating capacity of the resins when present at high concentrations.
In this specific application, since activated carbon is efficient in removing long-chain PFAS, Chemra and its partner can propose a solution that combines the two complementary media: the activated carbon that removes the organic matter and most of the long-chain PFAS, while the resin is used as a polishing step for the short chains only.
This increases the operating capacity of the resins as they are not exhausted by the long chains. In such a situation, the layout will be as presented in Figure 3
In conclusion, per- and polyfluoroalkyl substances (PFAS) provide exceptional resistance properties in paints. The substances used today have less impact to the environment than those used in the past. However, due to the high concern surrounding these products, industries must reduce their dispersion during production. Innovative solutions exist for all types of PFAS (both long and short chains) and for all situations, as each case is specific and requires testing and recommendations from specialists such as SG Projects and Chemra GmbH.
DeGeest will now be able to offer also the technologies developed by Eurosider, that provide a more consistent finish with both liquid and powder applications.
DeGeest Corporation has recently announced that it has acquired the North American rights to the patented technologies and equipment from Eurosider: through the new strategic agreement, the company is now able to bring widely accepted finishing solutions from Europe to manufacturers in North America. Since 1973, Eurosider has been globally renowned for manufacturing advanced technologies and developing innovations for nitrogen-modified air systems in the industrial liquid painting and powder coating equipment sector. The business possesses now twentytwo recognised patents in all the most
industrialised countries in the world, including Nitrotherm® Spray and Polifluid® Instead of compressed air, these two technologies use nitrogen as a carrier to deliver a more consistent finish to liquid and powder finishing applications, eliminating variables such as temperature and humidity in the process and delivering up to 30% on system savings.
“Manufacturers can add Nitrotherm or Polifluid to their existing manual operations today, with zero interruption or change to current processes. Eliminating variables is an important step in preparing for full automation later, when technologies such as self-learning
robots can be added. With Nitrotherm or Polifluid, all you have to do is to plug it into your current system – even if it is manual –to get optimised quality and efficiency,” has declared Derek DeGeest, the president of DeGeest Corporation.
Founded in 1976, DeGeest is a thirdgeneration family-owned business with a history of innovation and excellence in manufacturing. As a matter of fact, from its 12,729 m2 (137,000 square foot) facility located in Tea (South Dakota - United States of America), the organisation is always striving to push boundaries on what is possible in manufacturing through its business lines ‘Steel Works’, ‘Finishing’ and ‘Automation’.
The technology from Eurosider was previously available through Coating Delivery Technology (CDT), which had been acquired by DeGeest. Moreover, DeGeest also integrates LestaUSA, in order to offer the integration and technical support on Lesta robots and software for industrial liquid painting and powder coating applications on metal, wood, ceramics, plastics and composite materials.
“Think of this partnership as ‘The Power of Three’: we have been partnering with Lesta and its self-learning robotic technology for years, so it is exciting to add Eurosider to the mix to be able to bring a well-rounded solution to more customers,” has concluded DeGeest.
For further information: https://degeestcorp.com
Mipelon UHMW-PE fine powder from Mitsui Chemicals provides an effective alternative to PTFE for improving abrasion resistance in paints and coatings.
The spherical UHMW-PE fine powder from Mitsui Chemicals Europe Mipelon can offer a high-performance substitute for PTFE –thus enhancing abrasion resistance and chemical resistance in paints, powder coatings, water-based coatings and solvent-based coatings, as well as rubber-coated rollers, automotive rubber profiles, and anti-blocking agents for films.
While the lower melting temperature of UHMWPE (around 135 °C) limits its use compared to PTFE, Mipelon is effective at temperatures up to 120 °C, with the PM200C grade able to withstand temperatures up to 200 °C in hydrocarbon oils. Unlike PE powder, Mipelon does not swell at higher temperatures and maintains its shape and function. Moreover, Mipelon delivers a lower coefficient of friction and improved abrasion resistance at the same dosage compared to PTFE, offering a costeffective solution. With a density of 0.97 g/cm³,
which is about half that of PTFE, it also contributes to weight reduction. Its molecular weight is around 2 million g/mol, and its spherical particles are notably small, with an average particle size (D50) of around 10 µm for the PM-200 type. Other grades, such as XM-220 and XM-330, have D50 values of 30 µm and 65 µm, respectively. The finer powders are ideal for paints and coatings.
Lastly, Mipelon’s smooth, spherical particles and narrow particle size distribution enable excellent dispersion, outperforming PTFE in terms of lower friction and abrasion, even under long-term stress. Mipelon also demonstrates superior chemical resistance to acids, alkalis, organic chemicals and absorbs minimal moisture.
For further information: jp.mitsuichemicals.com/en/special/uhmw-pe/ index.html
Audi’s new paint shop facility focuses on efficient and sustainable processes, supporting both combustion and electric vehicle production.
Audi has inaugurated a cutting-edge primer facility at its Neckarsulm plant (Germany), marking a significant step towards more sustainable and efficient production processes. This new facility, designed to accommodate both combustion and electric vehicles, reflects Audi’s commitment to innovation and environmental responsibility.
“With the investment in the new facility, Audi is setting the course for continuing its journey towards e-mobility and aligning the Neckarsulm site for a sustainable future. The construction project is an important milestone in the plant’s development and part of a future-proof infrastructure for production,” has stated Fred Schulze, Plant Manager at the Neckarsulm site. The new paint shop facility covers 12,000 m2 and will handle the primer application for all models produced at the Neckarsulm site, as well as the nearby Böllinger Höfe facility. This includes the Audi A5, the upcoming A7, Audi Sport models, and various all-electric vehicles.
“With the refurbished paint shop, we have one of the most advanced facilities in the automotive industry with modern working conditions. This investment underlines our commitment to sustainability and ensures the future viability of our site,” has commented Rainer Schirmer, Chairman of the Works Council.
Innovative technologies for corrosion protection
Audi’s new facility incorporates the latest in corrosion protection techniques, including E-coating. This process immerses vehicle bodies upside down, ensuring better coverage and minimising dirt deposits. A new transverse drying process also makes the cathodic dip coating more energy-efficient, ideal for electric and hybrid vehicles requiring longer drying times.
The facility introduces a revolutionary thin-film pre-treatment process, replacing the traditional phosphating method. This new technique applies a 0.2-micrometer-thin layer of zirconium and silicon compounds, offering corrosion protection and serving as a primer base. The process significantly reduces waste, water, and energy usage, contributing to Audi’s Mission environmental program.
“The innovative thin-film technology in pre-treatment, combined with the new cross-drying process, makes a special contribution to the efficiency and sustainability of the new primer facility. This allows us to significantly reduce our electricity and water requirements and make an important overall contribution to our Mission: Zero environmental program,” has added Ursula Noll, Head of Production Planning Paint Shop Corrosion Protection.
The A22 primer building is connected to the top coat facility via a newly constructed bridge. The top coat facility itself has undergone major restructuring, achieving energy savings of 50 kilowatt/hours per vehicle by switching to a dry paint separation process. This new method, which captures paint mist with filters instead of water, allows for the reuse of over 90% of the filtered air, reducing the need for energyintensive fresh air conditioning.
Moreover, Audi has eliminated the need for a separate filler drying stage by introducing a pre-zone paint process - further reducing energy consumption by up to 140 kilowatt/hours per vehicle.
For further information: https://www.audi-mediacenter. com/en/press-releases/audi-opens-new-primer-facility-inneckarsulm-16306
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.
In the new 3D WAVE machine, the innovative “Rotowave” dyeing system allows the dye to reach every area of the pieces, thus ensuring high precision and uniform coloring.Thanks to the integrated pre- and post-rinse and the drying system, it is the complete and definitive solution for single-color dyeing.
ALL-IN-ONE
pre-rinsing - dyeing - rinsing - hot drying
OPTIMAL DYEING OF COMPLEX SURFACES thanks to the Rotowave system
LOW OPERATING COSTS energy consumption, dyeing and disposal
HIGH PRODUCTIVITY
1 complete cycle in less than 60 min.
WORKPIECE HOLDER with lid for partial filling
Reducing Overspray, Increasing Productivity: Mascar Installed a New Purification System for the Effluent of Its Coating Booths’ Water Curtains
Powercolor: Coating Innovation Accelerators Thanks to Dense Phase Application, 3D Part Recognition, and Inline Cataphoresis
When the Coating Plant Engineering Company’s Technological Approach Makes a Difference
At
IMEL, a company specialising in the design and installation of coating systems since 1964, also offers customised 5.0 solutions for their optimisation.
In the ACE sector, characterised by the machining of parts with a large mass and size, production processes are notoriously energyintensive. IMEL has developed a series of customised solutions that facilitate compliance with the Italian government’s Transition 5.0 Plan1 while reducing the energy requirements of manufacturing operations. An essential requirement to qualify for tax relief is the ability to demonstrate a reduction in energy consumption, measured per production batch and per m2 treated.
1 The Transition 5.0 Plan set up by the Italian government in complementarity with the Transition 4.0 Plan is part of a broader strategy aimed at supporting the digital and energy-related transformation process of companies and makes 12.7 billion Euros available to them over the period 2024-2025. https://www.mimit.gov.it/en/
To this end, IMEL developed advanced software to monitor energy consumption, optimise processes, and simplify operational management, called i4paintshop.
i4paintshop: what is it, and what is it for?
An ecosystem of modules with different functions to optimise the management of coating processes;
an advanced platform that manages data through databases, algorithms, and tested filters;
an essential tool for recording the reports needed to obtain tax incentives;
an asset for real-time interfacing with the system for production management, preventive and predictive maintenance, paperless document management, and technical support provided by IMEL’s Service team.
In particular, the i4environment-5.0 module is the “Green 5.0 solution” – a smart software program that monitors and certifies consumption reduction and environmental impact through interconnected components and systems. It is also a driver for integrating the investment made with photovoltaic systems, thus enhancing overall energy efficiency.
IMEL offers diversified solutions according to specific customer requirements and plant characteristics:
high-efficiency heat generators;
thermal recuperators for heat recovery;
electrical power modulation systems;
oven hybridisation.
Using high-efficiency generators ensures energy savings of up to 5-8% measured in TOE, enabling access to tax credits under the incentives programme. Heat recovery systems can reduce energy consumption by up to 10%, especially in the ovens, the devices with the highest energy
impact. This reduces short-term operating costs and allows access to tax benefits. Finally, electrical power modulation systems guarantee reduced consumption by up to 15% for a rapid return on investment.
The i4paintshop platform’s pillars to measure and thus improve the operating costs of coating plants
Productivity: continuous improvement of production efficiency;
Efficiency: reduced operating costs through innovative solutions;
Quality: consistently improved product quality;
Maintenance: targeted planning based on the actual hours of use of each piece of equipment.
IMEL’s aptitude for innovation is what distinguishes its solutions, guaranteeing high performance and concrete results. The IMEL team is fully available to analyse plants and requirements and find the perfect solution for each customer.
For further information: www.imelspa.com
The new manufacturing plant that Volvo Group will establish in Monterrey, Mexico, will produce heavy-duty vehicles under the Volvo and Mack brands and will feature a dedicated cab painting department.
The Volvo Group will build its new Mexican heavy-duty truck manufacturing plant in Monterrey. As announced, the plant will supplement the Group’s U.S. production and provide additional capacity to support the growth plans of both Volvo Trucks and Mack Trucks in the U.S. and Canadian markets, and Mack truck sales in Mexico and Latin America. The plant is expected to be operational in 2026. Monterrey provides significant logistical efficiencies for supporting sales to the southwestern and western regions of the U.S., and to Mexico and Latin America. With its proximity to the U.S. border and well-developed infrastructure, the Group considers Monterrey an ideal location for building a mature supply and production ecosystem.
Growth in North America is a strategic priority for the Group, and this investment is part of a comprehensive effort to increase the strength
and flexibility of the Group’s industrial footprint and supply chain in the region. This includes an agreement to acquire Commercial Vehicle Group’s (CVG) production plant in North Carolina, which produces cabs for Mack’s heavy- and medium-duty trucks, for approximately USD 40 M (SEK 410 M). The agreement was announced August 1 by CVG and is expected to close in the second half of this year.
The Monterrey plant represents an investment of approximately USD 700 M (SEK 7.2 billion) and will focus on production of heavyduty conventional vehicles for the Volvo and Mack brands. It will be a complete conventional vehicle assembly facility including cab body-inwhite production and paint.
For further information: www.volvogroup.com
Mascar, a leading agricultural machinery manufacturer, recently installed a Skimmerflot 5000 system to treat and purify the waste water generated by its coating booths. To ensure greater efficiency and further commit to sustainability, it turned to industrial water treatment expert Water Energy to clean the liquid that feeds their overspray-capturing water curtains.
Lean manufacturing is a management approach that aims to optimise efficiency by reducing waste and unnecessary costs while improving the quality and flexibility of production processes. Conceived in Japan in the 1950s, this operating model was made famous by Toyota, which adopted it as the basis of its workflow. Lean production focuses on a philosophy of continuous improvement involving all company levels, from managers to operators, and promoting greater collaboration and communication among all parties. Adopting this approach means not only reviewing every process to eliminate inefficiencies but also focusing on creating value for the customer as a core concept that is placed at the centre of every activity. Essentially, it is about doing more with less: less resources, less space, less time, and above all, less waste.
In the agricultural machinery sector, implementing lean production principles is a significant step towards innovation. The ability to meet customer needs more quickly and flexibly while maintaining high quality standards is a crucial competitive advantage. It enables companies to respond to the challenges of today’s market, which is increasingly focused on customisation, data control, and sustainability,
by optimising their entire production processes and ensuring superior end products.
Mascar, a leading manufacturer of seeding and haymaking machinery that has made lean production one of the factors of its market success, has recently decided to take on some new challenges by investing not only in the continuous optimisation of its production processes but also in environmental sustainability, continuing the “green” evolution process it began in 2011 with the installation of photovoltaic panels (which meet about 50% of the energy needs of its metalworking department and 60% of those of the coating and assembly areas).
In the coating department, in particular, this resulted in the installation of an advanced water treatment system for the liquid coming from the application booths’ overspray-capturing water curtains. For this project, Mascar turned to Water Energy (San Pietro in Casale, Bologna, Italy), a company recognised for its expertise in the industrial water treatment sector, which suggested implementing a process to remove sludge from overspray-polluted water with a Skimmerflot device and revamping the existing scrubber system to reduce the maintenance and replacement intervals of paint stop filters and droplet separators.
A path of success: Mascar’s story between tradition and innovation
Mascar’s story began in 1998, when Antonio Maschio, a co-founder of the Maschio Gaspardo Group, embarked on a new entrepreneurial adventure by taking over a small local company already active in the agricultural machinery sector. “It was a brave decision, but with his vast experience and expertise, my father was determined to transform Mascar from an artisan business to an industrial enterprise,” explains Maria Teresa Maschio, who now manages the company with her brother Sante Maschio. “We capitalised on previous know-how to reorganise Mascar in every aspect, focusing on advanced technologies and continuous innovation. Our decision not to follow the path of producing a full line but rather specialise in two well-defined sectors, i.e. haymaking and seeding, has made the difference. It has enabled us to offer top-quality, technologically advanced machines designed for highly
demanding market niches.” In particular, in the haymaking field, Mascar mainly specialises in round balers and baler wrappers, whereas in the seeding one, it focusses on precision planters, seed drills, front tanks, and cultivators.
In the last few years, Mascar has made significant technological advances to respond to the needs of the agricultural industry, which is constantly evolving and increasingly oriented towards digitalisation. Indeed, knowledge and control of data are crucial for today’s farmers: having the ability to accurately monitor how many seeds are planted, at what distance, and what the soil conditions are is vital for optimising production and ensuring high yields.
“We have invested heavily in making our machines more digital, equipping them with advanced technologies that provide farmers with the tools they need to monitor crops in real-time, improve productivity, and control costs. These investments have focused on electronics,
hydraulics, and mechanics, enabling us to meet new market challenges with a future-oriented vision,” adds Maschio.
“At the same time, Mascar has embarked on a path towards lean production to reduce processing times and increase overall efficiency without compromising quality. This complex project involves our whole organisation, as it entails a philosophy that goes beyond the manufacturing flow: it is a change that also affects our staff’s mindset and working methods. We started with the metalworking department, and we plan to extend this programme to assembly and coating by the end of this year,” states Emanuele Ghezzo, Mascar’s plant manager. The coating phase was also the subject of an investment aimed at improving sustainability and efficiency while contributing to the Mascar machines’ surface finishing quality. That entailed the revamping of the booths’ air purification system by inserting a floor sludge removal system to reduce the volume of coating sludge to be disposed of and
the upgrading of the existing scrubbers to minimise maintenance intervals. Water Energy took care of the whole project.
The coating of agricultural machinery: a cutting edge technological process
One of the distinctive quality aspects of Mascar’s agricultural machinery is the coating cycle it undergoes, a fundamental component of a technologically advanced production process. This phase not only gives agricultural machinery excellent aesthetics with automotive-degree quality but also plays a crucial role in protecting its substrates, which are constantly exposed to moisture, abrasive soils, and chemicals. The process begins with a pre-treatment phase including phosphodegreasing, a rinse with mains water, and a rinse with demineralised water. “The pre-treated components are first dried in a dedicated tunnel and then subjected to the masking stage to protect the
parts that are not to be coated.”
“In the first booth, devoted to primer application, an operator manually applies a two-component, water-based epoxy primer developed by Sherwin-Williams (Bologna) with state-of-the-art electrostatic equipment. After a flash-off step in a ventilated oven to remove surface moisture, a 2K acrylic top coat is applied on the parts,” Ghezzo explains. Both booths are equipped with spray guns from Graco’s XP range installed by Comaind (San Giovanni Lupatoto, Verona, Italy), which have enabled Mascar to achieve paint savings of over 30% while improving the quality of its finishes.
Mascar also installed dosing and mixing systems developed by Graco. “We supplied a Graco ProMix 2KE dosing unit and a 2KS multi-component system for precise mixing and fast colour changes,” indicates Davide Galvani from Comaind.
The water treatment plant: an integral part of an environmentally sustainable philosophy
Mascar has recently improved this coating process with a sludge removal system for its booths’ water curtains, a Skimmerflot 5000 plant supplied by Water Energy, which set up the entire chemical water treatment process. “The Skimmerflot unit is designed for the treatment and recirculation of water in coating booths and operates by mechanical separation of the sludge from the liquid. In the flotation process, denatured paint loses its adhesive properties, and thanks to the addition of a special flocculant, it aggregates into flakes that float on the water’s surface. That ensures easy separation and removal of the sludge, preventing it from settling on the bottom of the coating booth’s tank. In the water return circuit, we dose a coagulant that prevents the residual paint from reaggregating with water, which is recirculated to feed the overspray-capturing water curtains, whereas the paint sludge, mechanically separated and dewatered by the Skimmerflot sludge separator, is collected in big bags ready for disposal,” illustrates Tommaso Ponara, the owner of Water Energy.
“Besides installing its Skimmerflot, Water Energy revamped our existing scrubbers with an air cleaning system featuring self-cleaning bars with hollow cone nozzles that purify the air of residual overspray. After passing through the floor water curtain, the air leaving the booth is conveyed into a channel that runs parallel to the tank and then sent upwards, passing through the scrubbers for further wet cleaning before being recirculated back into the booths.”
The system thus ensures optimal cleaning of the droplet separators and reduces the replacement intervals of the paint stop filters, preventing the emission of potentially harmful solid particles as well as the deposit of dirt particles on the coated workpieces in the booths.
The continuous recirculation of clean water keeps the removal system efficient and reduces the amount of water to be disposed of. In addition, the handling of the collected sludge is simplified by the automatic separation process, which reduces its water content and limits the volume of the big bags to be disposed of, resulting in significant cost savings.
The sludge collected in a big bag before being disposed of.
“Water Energy’s solution has significantly improved our coating line. Recirculating only purified water also makes the protection filters and water recirculation pumps last longer. As a result, we have experienced fewer plant downtimes and greater production continuity,” Ghezzo notes.
Mascar handles 95% of the production of its agricultural machinery in-house by carefully following every step of the process, from metalworking and finishing to assembly and shipping. Its two factories, covering a total area of 27,000 m², are equipped with advanced technologies such as DDL fibre laser cutting, CNC machining centres, and welding robots, which enable extremely precise processing of the raw material used, pickled sheet metal.
“Compared with 20191, when ipcm® first visited our site, we have switched from a CO2 laser to a DDL fibre laser system, which allows us to cut steel up to 25 mm in thickness four times faster and with significant energy savings,” explains Ghezzo. In addition, the welding department has been updated with state-of-the-art robots, which ensure greater efficiency, precision, and process repeatability. This configuration enables Mascar to monitor every manufacturing stage, ensuring product reliability and reducing time to market.
1 Continuous Technological Innovation and Paintshop Updating for High Quality Agricultural Machinery: Mascar’s Winning Strategy, in ipcm® no. 60, November/December 2019.
After the metalworking and assembly stages, the products undergo rigorous quality controls and finally reach the coating department.
A successful synergy
“We chose Water Energy on the advice of Comaind, our long-standing partner for coating, which has been with us for decades and has contributed significantly to the growth of Mascar,” indicates Maria Teresa Maschio. “Our collaboration with Comaind dates back to when we transitioned from one-component to two-component paint products, and since then, it has supported us at every stage to improve our application processes and reduce colour change times.”
Last year, Mascar was faced with an issue related to the frequent replacement of paint stop filters in its coating booths, which was significantly increasing operating costs. “We have known Water Energy for years, and after a thorough analysis, we suggested Mascar relied on them for a solution to reduce air filtration costs,” says Galvani from Comaind. “The goal was clear, and together, we managed to hit it.” It was to solve this problem that the Bologna-based company revamped the existing scrubbers, thus reducing the need to replace filters and optimising process efficiency.
The resulting partnership goes beyond a mere supply relationship: Water Energy is not just a provider but an actual partner for Mascar.
“When you work with people and organisations that share your goals, you feel at home,” Ghezzo concludes.
The strength of Europolveri products does not derive from the sole mixture of carefully selected raw materials, but rather from the people who study, model and formulate powder coatings thanks to more than 40 years of experience, and provide customers with the best solutions on the market A clear corporate philosophy and a shared vision have allowed to supply a vast range of products for three generations With more than 1000 products available in stock and over 40,000 already formulated, Europolveri offers infinite solutions to customer requests
Alessia Venturi ipcm®
Combining a powder finish with a cataphoretic primer is a guarantee of unrivalled coating durability. Let us look into how coating contractor Powercolor (Vallese di Oppeano, Verona, Italy) has embarked on an investment path that began with upgrading its powder feeding, automation, and application technology for large-sized parts in cooperation with Gema Europe and will end with starting up an inline cataphoresis process.
Many of us – some of us in our youth, others in our childhood – have certainly seen old cars on the road with body or underbody parts so rusted and deteriorated that they were punctured or detached from the bodywork. Those under 40, however, probably have no memory of this. It is something that has not belonged to the present for many years now: more precisely, ever since electrodeposition technologies – anaphoresis, which has now almost
disappeared, and cataphoresis – entered the automotive industry as the anti-corrosion treatment of choice for cars, trucks, and commercial vehicle bodies, to be applied before the liquid or powder finish. Thanks to its exceptional corrosion protection properties, its extreme ability to penetrate and cover surfaces, and its function as an aesthetic primer for superior quality finishes, cataphoresis has become widespread in the general industry, too, not only among Tier 1 and
2 suppliers in the automotive world but also in other market niches such as home appliances, radiators, and off-road vehicles. Today, the industrial coating sector considers cataphoresis the key treatment for maximum durability, and more and more fields are becoming strongly inclined to adopt it. As a result, cataphoresis lines in Europe are multiplying, although still few, if we exclude automotive OEM plants. Combined with one or more powder coats, this process ensures unparalleled durability. At the same time, to provide not only durability but also consistency among batches, cataphoresis + powder lines and processes must be up-to-date with the latest technology, as well as hyper-controlled and tracked.
“There is a widespread demand for more durable coatings coming from all industrial segments indiscriminately,” says Giuseppe Di Maria from Powercolor, a company specialising in powder coating heavy and light metal fabrications for various manufacturing sectors, first and foremost agricultural and earthmoving machinery. “Cataphoresis is a complex operation: it requires careful daily management and must be constantly fed in order to give the best results. However, despite all these critical issues, it is the only organic metal treatment process that can provide superior quality, durability, and corrosion resistance. Combined with powder coating in one or multiple layers, it is the perfect treatment for all those components that must endure the daily action of aggressive
atmospheric agents, mechanical and chemical stresses, and harsh environments.
“To meet this market demand and characterise Powercolor as a company that can meet the highest quality standards, I decided to pursue an innovation project that, as a first step, would update our powder application systems to the latest technology and, as a second step, would include the inline integration of a cataphoresis process.
As our partners in this journey, I chose to rely on Gema Europe and Visa Impianti, respectively. As of today (September 2024, Ed.), we have completed the first part of the project with success and extreme satisfaction on my part, whereas the second part is in its initial stages and will lead to the start-up of a cataphoresis plant in the first half of 2025.”
Powercolor was established in 2021 as a spin-off of another longstanding coating contractor in Verona, Maxicolor, which had been in operation since 1989. At its origin was the decision to implement an innovative, high-performance nanotechnology pre-treatment system from DN Chemicals into the company’s new coating plant, which soon pushed the performance degree of the coatings applied by Powercolor to much higher levels than those applied by Maxicolor. More than
doubled durability, excellent mechanical and chemical resistance, and corrosion protection properties exceeding 1,000 hours in salt spray tests attracted the attention of many of its customers, which gradually opted for Powercolor’s coating services.
Today, Powercolor is a dynamic company specialising in high-quality metal surface treatments for demanding industrial sectors, currently pushing the accelerator on innovation: it is no coincidence that it is carrying out an investment project exceeding 2 million Euros to update its powder coating plant to the latest finishing technologies.
As mentioned, the first step, completed last spring, was upgrading its powder application technology in cooperation with Gema Europe (Trezzano sul Naviglio, Milan, Italy). Powercolor installed 16 automatic guns, 4 manual units, and a new OC10 powder centre with all-inone dense phase pumps, replaced the reciprocators in the existing booth, and integrated the second generation of the Dynamic Contour Detection system for 3D workpiece recognition with 3D-LiDAR sensors.
“The purpose of this large technological investment was to position Powercolor at a higher level in the market, expanding our capacity for sectors in which we are already present, such as agricultural and earthmoving machinery, while also reaching new ones, including the
automotive industry, by offering an additional high-quality process: cataphoresis,” says Giuseppe Di Maria.
“I had been considering for some time the implementation of Gema’s 3D part recognition system and the replacement of our feeding and application equipment with a dense phase unit, which, in my opinion, is much more suitable for Powercolor’s typical operations than traditional systems with Venturi injectors,” continues Di Maria. “Now that we finally have Gema’s complete equipment at our disposal, I am very satisfied and cannot wait to focus on cataphoresis – a project that we will conclude in 2025 and allow us to make a significant quality leap in the Italian contract coating landscape.”
As explained, Powercolor is pursuing a larger project that also includes the installation of a cataphoresis tank from Visa Impianti and the extension of Futura’s power & free conveyor to connect the cataphoresis station with the subsequent powder coating one. “We opted to implement inline cataphoresis for space reasons and aiming to meet the needs of our target markets while also opening up to new sectors, such as that of chassis for commercial vehicles: our coating plant’s usable dimension, 8,000 x 2,400 x 1,200 mm with a load bar capacity of 2,000 kg, gives us ample room for growth.”
Details of the investment in Gema’s technologies
“The project to upgrade our application technology entailed the preservation of our existing booth, which dates back to 2009 but is still perfectly functional”, says Marco Peduzzi, Area Manager at Gema Europe, detailing the investment made by Powercolor. “We supplied an OptiCenter® All-in-One OC10 powder centre, which features the latest Gema technology: it is the first one installed in Italy. It ensures maximum output with minimum footprint thanks to the absence of gun control modules, since the technology for dispensing and charging the dense phase powder is integrated into a single device.
“The heart of the OptiCenter is the OptiSpeeder powder hopper, which optimally conditions the powder by fluidisation; it also has a large inclined opening for quick and easy access inside the powder container. The closed-loop powder circuit is automatically controlled, ensuring a clean work environment and greater efficiency. Weight detection is fully
integrated into the precision load cell: the fresh powder contained in the cone is weighed and handled by the batch management system of MagicControl 4.0. This makes it easy to record fresh powder usage for each batch, even when changing powder bags, and to monitor information in real-time on the GemaConnect dashboard.”
“At a later stage, we incorporated the second generation of the Dynamic Contour Detection system, which uses 3D-LiDAR sensors, to minimise pre- and post-finishing operations, which Powercolor performed frequently,” Peduzzi adds. “This system uses laser scanners to detect most shapes, even with complex components, and ultimately ensures high-quality coating results. The dynamic contour detection process takes place in two steps: after dynamic part recognition using laser scanners that measure the distance to the workpiece and calculate its contour, the data collected is sent to MagicControl 4.0, which segments the scanned object according to the guns’ layout and ‘translates’ it
into precise axis positions and gun settings. Each axis is managed independently.”
“As coating contractors, we handle very diverse and complex parts,” comments Giuseppe Di Maria. “Before installing the 3D part recognition system and the new Gema OC10 unit, we had 4 operators tasked with touch-up operations either before or after automatic application, sometimes even both, in order not to stop the chain and not lose productivity. Now, with these new systems, I am really satisfied because we no longer need to stop the conveyor, and we require no more than two touch-ups in the most difficult-to-reach areas. Therefore, I could devote those operators to other activities.”
“Our Smart Inline technology with straight path design guarantees a constant, gentle powder flow, ideal for producing films with uniform and repeatable thicknesses,” explains Marco Peduzzi from Gema. “Also,
since the reciprocators move according to the workpieces’ geometry identified by the Dynamic Contour Detection system, the amount of atomised powder is the same at the top, bottom and in the centre. Considering that the usable dimension of Powercolor’s booth is 8,000 x 2,400 x 1,200 mm, the widest point of a component is often in a central position in relation to the conveyor, whereas its narrowest section is at the bottom. The constant pitch between the nozzles combined with the dense phase distribution of the powder, which creates a consistent, soft cloud, ensures uniform thicknesses over the entire surface of the parts, eliminating the need for touch-ups. In any case, we also supplied Powercolor with 4 manual units for maximum flexibility in the few touch-up operations needed, but above all to coat individual parts or load bars with special colours that are not recovered nor managed by the powder centre.”
“The investment project that I have initiated at Powercolor is not limited to hardware, i.e. process plant engineering, but also entails the extreme digitalisation of the plants – both the current powder coating one and the cataphoresis one to be installed soon,” states Giuseppe Di Maria. “I am having management software implemented that can completely track the processing of every order, from the receipt of the materials sent by our customers to the finished parts ready to be packaged. Such traceability also includes photographs of incoming materials, process phases, outgoing materials, and any non-conformities.”
More specifically, when starting to process an order, the required raw material is photographed in its delivery conditions. Once the coating phase has begun, each load bar collects data on pre-treatment, coating types, cycle times, temperatures, bath pH, and demineralised water conductivity.
“Our spray pre-treatment phase includes 7 stages and enables us to treat cold-rolled steel, hot-rolled steel, Sendzimir and electrolytic galvanised steel, hot-dip galvanised steel, and even aluminium, which, however, we only paint for indoor applications because we do not have a Qualicoat certified cycle,” explains Giuseppe Di Maria. “DN Chemicals has developed this process phase. As a first step, we can carry out phosphate pickling with Denacid 545 FD for hot-rolled steel, degreasing with Denacid 539 ZN for galvanised steel, or phosphating with Denphos 183 SC for cold-rolled steel and aluminium. After several rinses, first with mains water and then with demineralised water produced with our well water demineraliser, equipped with a sand and carbon filter and a softener, the operation ends with a multi-metal nanotechnology passivation stage with Dollcoat SA 115. This high-performance pretreatment cycle has won us numerous customers in a variety of industries.”
“The cataphoresis process will also be fully traced,” Di Maria points out. “After that, we will take another photograph of the parts to prove that the treatment has been carried out and check for any non-conformities. In the powder coating booth, Gema’s MagicControl 4.0 software will display values such as consumption rates, square metres coated, and spraying parameters. Two different test stations in the curing oven will measure dwell times and temperatures. Finally, we will take a third photo of the painted material after coating and cooling. Each of our customers will thus receive a data sheet showing the complete process undergone by its products and rest assured that its material is treated the same way 365 days a year.”
The success of the dense phase pump technology
There was much scepticism when the dense phase powder feed technology entered the coating market. Today, 8 out of 10 plants built by Gema implement it. “I am extremely pleased with the choice I made. I have noticed a slight decrease in powder consumption, but what is impressive is the increase in finishing quality,” says Di Maria. “There are also benefits in terms of maintenance: the new dense phase equipment has a total maintenance time of 35-40 seconds, unlike its first version, which took 15 minutes. In terms of plant components, the dense phase pump sleeves have a service life of 2,000 hours, regardless of the type of powder applied. With conventional Venturi injectors, on the other hand, the wear rate of the suction system’s float is closely related to the type of powder sprayed: the more abrasive the powder, the more frequently the float needs to be replaced. Generally speaking, I can confirm that the combined use of the powder centre with the dense phase pumps and the laser scanner system for part recognition takes coating quality to a higher level, with maximum automation and reduced raw material consumption.”
FAE specialises in designing and producing heads for tractors, excavators, skid steers, special vehicles, and tracked carriers for forestry, agricultural, demining, and road works.
FOCUS ON TECHNOLOGY
SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES
Monica
Fumagalli ipcm®
Two companies united by the same technological approach to customer needs: FAE, a world leader in the production of forestry, agricultural, road, and demining machinery, has chosen to work with SAVIM Europe for the installation of a new coating system that combines manual and automatic application in a small space and handles bulky parts efficiently thanks to a CM Automazione conveyor. An example of how a plant engineering company can grasp its customers’ needs and turn them into the ideal design, regardless of the size of the coating line.
Acompany’s technological approach is a method or strategy involving the use of technology-based tools, devices, systems, and solutions to address, solve, or improve specific problems or processes. In manufacturing, this calls for a focus on continuous innovation, the updating of skills, and the ability to adapt to changing technologies – exactly what we report about in the pages of our magazines specifically dedicated to industrial coating processes. Regardless of the size and complexity of the line to be designed and built, a company’s technological contribution lies in the engineering and technical skills that enable it to customise a project according to space, production, and customer requirements. Here, small footprints and special needs are precisely the technological challenges that allow a plant engineering firm to prove its actual know-how.
“This approach also embeds our mission,” says Gianluca Morandi, the Supply Chain Manager of FAE Group S.p.A., which specialises in the design and production of heads for tractors, excavators, skid steers, special vehicles, and tracked carriers for forestry, agricultural, demining, and road works. “Our company focuses on technological innovation and construction quality to guarantee its machines’ maximum performance and reliability. Each product, each accessory, each optional component is designed with the utmost accuracy, the highest quality materials, and the most advanced technologies. The task of the vehicles we put on the road is to make it as easy and efficient as possible to operate them according to the specific applications, conditions, and environments.”
At the beginning of 2023, FAE installed a new coating plant at its headquarters in Fondo (Trento, Italy). “We turned to SAVIM Europe Srl (Arbizzano, Verona, Italy) because it was the only plant engineering company able to grasp our needs and turn them into the project we had in mind, designing a plant with the perfect size for the limited quantity of batches we process daily without letting this limit the technological value of the system, which is in fact of high quality.”
Manual application in the water-curtain spray booth. The inside of the water-curtain spray booth.
FAE’s products, from forest to road
Founded as an artisan business in 1989, FAE started out by designing and building equipment for forestry machines. In the early 2000s, the company integrated its production of forestry mulchers with accessories for construction machinery and road planers. In 2005, it inaugurated a new line for the manufacture of tracked carriers. Today, FAE employs around 400 people and has a global turnover of 170 million Euros. Its portfolio consists of 3 macro-lines including 90 products and 400 models: Land Clearing, designed to speed up and facilitate a wide range of forestry and agricultural tasks, operating in woods and forests, farmland, rivers and canals, natural areas, and urban greenery; Construction, for use in construction sites on roads, highways, paths, quarries, mines, and infrastructure in general; and Demining, for the reclamation and restoration for civil use of otherwise dangerous and unusable land, with products ideal for roads, paths, and agricultural and forestry areas where mines are present.
“75% of our products carry the FAE brand, whereas the remaining 25% are made for major global OEMs of which our company is a supplier,” explains Morandi. “We are present in the world’s most strategic markets for this sector: in North America, particularly the United States and Canada, as well as in France, Germany, Australia, and now also China.”
Production is carried out exclusively in three Italian factories. The headquarters is located in Fondo, in the heart of Trentino’s Non Valley, and houses the administrative, sales, and marketing divisions, the technical department for product design, the pre-assembly, coating, and testing departments, the warehouse also for spare parts, and the
logistics division. A plant in Vipiteno (Bolzano) is tasked with machining one of the most critical components, the rotor. Finally, a production site near Vicenza manufactures semi-finished components from coils.
“All our machines and accessories,” notes Morandi, “are designed to make a difference not only in the task they perform but also for the planet, given the importance of some of their applications to our world. This is what each person in our team, each partner, each customer works for every day: this is exactly the spirit of FAE.”
From land clearing to demining, the contribution of this company’s products is especially critical for recovering and maintaining areas subject to environmental disasters, such as fires, and restoring areas destined for new uses. Unfortunately, forest fires are a growing phenomenon, amplified by climate change and poor land management in many exposed areas. “If we consider that since 2000 in the United States alone, which is one of our main markets, fires have destroyed seven million acres of land annually1, and that their rate of destruction has sadly doubled in the last twenty years, figures are indeed worrying. The social, environmental, and economic impact of such calamities has drawn attention to the importance of fire management and prevention worldwide. And that is where FAE’s equipment truly makes a difference. “One of the most effective measures to stop the spread of a fire is creating firebreaks, i.e. areas free of vegetation within forests or natural areas. Not only do they contain the fire in a delimited area, but they 1 https://ourworldindata.org/wildfires
can also be used by wild animals as a safe haven from the flames and by fire-fighting teams to extinguish the fire and carry out the necessary work to maintain the vegetation. Forestry mulching is environmentally friendly and economical and is currently the most efficient way to preserve soil quality. During this process, our machines leave a nutritious mulch on the soil to provide moisture and vital nutrients and suppress unwanted plant species. Our products are, therefore, actively involved in the fight against fires, and we are proud to help save our forests for future generations.”
The need to expand its coating department, previously consisting of one booth for manual application, arose for FAE with an increase in production volumes. “The new plant has soon become one of our strengths in guaranteeing the quality of our components. It is equipped with two static booths for manual application and a semi-automatic booth equipped with a robot and linked to a power & free conveyor by CM Automazione (Giussano, Monza e Brianza, Italy) handling 12 load bars with a maximum capacity of 700 kg each. The robotic booth allows much faster work, whereas the manual ones ensure high flexibility, as they can treat various types of components, including large ones which are moved with a manual conveyor with pneumatic switches designed by SAVIM. The flash-off and drying tunnel is linked to a water heating system fed by a biomass heating plant. The entire line was integrated into the ERP system to monitor the progress of each stage through the company’s management software.
Coating small batches: FAE’s requirement
The company did not need to install a large, complex coating line. “Most of the components we use for our products,” Morandi emphasises, “are coated by contractors or in-house at our other two sites. This factory treats pre-assembled components that must be coated for aesthetic purposes. The design for the new system had to reconcile our need for maximum versatility to handle parts of different types, sizes, and shapes with the limited space we had available. One of the characteristics of this factory area is that it has very little space to handle large workpieces. Therefore, we installed a 26 x 13 m plant including the two static booths – i.e. a dry spray booth for manual application on parts weighing up to 1,500 kg and a water-curtain spray booth – and the water-curtain robotised booth for semi-automatic coating of parts up to 1.80 m. They are all linked to a Graco coating management unit with a high-pressure pump.”
From left to right:
The inside of the dry spray booth.
The area of the plant dedicated to semi-automatic application.
Coating with the robot.
“Only 20% of the components sent for coating are pre-treated with manual degreasing; for the others, no mechanical or chemical pre-treatment is necessary. This is another special aspect of our coating process,” states Morandi. “We carry out one-coat and two-coat (primer + topcoat) application processes. For one-coat applications in the robotised booth, where we paint the rotors, the most important components in our production, we use a DTM water-based coating supplied by Inver2, the INVERPUR MU”. “It’s a two-component water-soluble primer/finish with acrylic resins and formulated with anti-corrosive pigments,” states the Sherwin-Williams technical team. “It’s particularly suitable where aesthetic appearance is of primary importance and a simplified painting process using a single product is required: it can indeed be used, as in this case, as a DTM (direct-to-metal) solution. The product forms a hard and elastic film with a gloss level of up to 60-65 gloss, offering good adhesion to steel, aluminium, and cathodic coating supports, as well as good corrosion resistance. Thanks to its acrylic resin formulation, it also provides excellent light resistance.” For the other parts, depending on their characteristics, two-component paints applied in one or two coats with cup guns are used: the quantity of product applied is so limited that no mixing machine is required.
In addition to the perfectly tailored design, another feature of this line FAE particularly appreciated is the ease with which the components can be handled and finished in just a few hours, thanks to the replacement of the overhead crane with a specially designed conveyor.
2 A brand of The Sherwin-Williams Company
From top to bottom:
One of this company’s main challenges is handling large workpieces.
The unloading area.
A finished part.
“SAVIM not only provided us with valuable assistance,” Morandi notes, “but also acted as the project’s prime contractor, interfacing with the other suppliers of the line’s functional devices, from CM Automazione for the conveyor to CMA Robotics, specialising in the design and construction of coating robots, and Hydro Italia, responsible for designing and installing the booths’ water treatment system.”
The articulated robot
“The GR 630 articulated robot,” says Marco Zanor, Sales Director at CMA Robotics (Pavia di Udine, Udine, Italy), “is an electronically controlled machine with six degrees of freedom, designed to automatically perform both liquid (as in this case) and powder coating operations on metal, wood, and plastic surfaces. The robot’s arm ensures maximum manoeuvrability thanks to a system of joints, perfect pneumatic balancing via the patented smart balance system, and special lightweight alloys. Additional flexibility in use is achieved through the particular wrist configuration, which allows each axis to rotate 360°, making it easy to reach any point on the workpieces. For
this specific project, we installed our latest self-learning technology, called VR Tracking, which enables robot programming without needing to physically move its arm. Essentially, we use the robot’s gun, which can be detached with a very simple mechanism, and then perform the painting of the object as if it were a manual spray gun. After reattaching the paint gun, the robot can repeat the cycle executed by the operator. An additional advantage is that the programmed trajectory can be modified at the terminal with a simple mouse movement.” Zanor adds: “The previous technology, which required moving the robot arm and was first invented and used in the 1970s, is now outdated. CMA Robotics, always at the forefront with its solutions in the painting sector, is a pioneer in the market with its new VR Tracking system.”
The spray booth water treatment system is a Hydrofloty 6M model installed by Hydro Italia (Medicina, Bologna, Italy). “We placed a submersible pump in an optimal position inside the booth to maintain the continuous movement of the tank water, which is then sucked by a pipe,” Davide Solmi, Sales Manager at Hydro Italia, explains.
“A special aeration system enriches the circulating mass with tiny air bubbles that adhere to the sludge layer, thus facilitating their surfacing (flotation) and removal with a skimming blade. The submersible pump conveys this mixture of water and air to the flotation unit, where sludge is separated from water. Before reaching this machine, a special chemical can be added to help separation. A pneumatically driven skimming blade continuously pushes the floating particles from the surface of the flotation unit tank to its outlet, from where they fall into a sludge container equipped with a disposable filter bag, which, in turn, is fixed to a movable container. The sludge accumulated on the bottom of the system can be disposed of, whereas the recovered, purified water flows by gravity back into the spray booth
“We could have simply built a plant with a single booth. However, we did not want to lose the flexibility that has always characterised our coating process, and SAVIM Europe’s team fully understood how crucial this aspect was for us. Thanks to their collaboration, already at the design stage, we opted for two plant systems with different characteristics in one space-saving structure. The automation solutions integrated have enabled us to improve the handling of parts within our factory, helping optimise the logistics of the entire department. We have also seen a further advantage in the line’s reduced maintenance frequency thanks to water filtration.”
FAE’s objective was to obtain a plant that was not oversized compared to its processed batches’ volume while still offering the necessary flexibility to handle any increase in production. “This goal was achieved thanks to the technological contribution and advice of SAVIM Europe, whose technical staff constantly aims to expand and improve its technical, production, and service structure in order to respond in the best possible way to the needs of its customers. Our company is happy to be one of them.”
via E De Nicola, 18 - I-20090 Cesano Boscone (MI) Italy - tel +39 0255210608 www.ravarinicastoldi.it - dive@ravarinicastoldi.it
SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES
By IVECO Spa Turin, Italy
IVECO partners with Metallica, supported them on the European legs of the M72 World Tour with electric and natural gas trucks and minibuses that were coated with a customised special livery.
Last November, IVECO announced a historic partnership with Rock & Roll Hall Of Famers Metallica during the launch event of its full range renewal in Barcelona. The brand would have supported the band during the European legs of the M72 World Tour, which filled stadiums across the continent from May to July 2024, averaging 70-80 thousand spectators per show. The M72 World Tour was the concert
tour organised by the American heavy metal band Metallica in support of its eleventh studio album 72 Seasons, which was released on April 14, 2023. The tour began on April 27, 2023 in Amsterdam and concluded on September 29, 2024 in Mexico City.
IVECO electric and natural gas trucks and minibuses joined the Metallica caravan, transporting the band and their equipment to their
concert locations in Munich, Helsinki, Copenhagen, Warsaw and Madrid. The announcement closed with the official launch video of IVECO’s new full range, enlivened by the ‘electrifying’ soundtrack of Metallica’s hit song “It’s Electric”.
Luca Sra, President, Truck Business Unit, Iveco Group, stated: “The launch of IVECO’s 2024 full range was a unique milestone in our history that opens an exciting chapter powered by our new energy. There could not have been a better time to announce a truly electrifying partnership. We were very happy to go ‘down the highway’ with this amazing band and crew onboard our alternative propulsion vehicles, driven by our shared vocation for supporting sustainable communities and pushing the boundaries for a better world.”
The customized livery of the Metallicabranded Iveco trucks
IVECO provided electric and natural gas S-eWay and S-Way Metallica Special Edition heavy-duty trucks, personalised by a talented artist with a specially designed livery in the colours of the band’s 72 Seasons album. The matte black bodywork is flooded by a bright yellow finish on the side of the cab, while the front grille bears the iconic airbrushed Metallica logo. eDaily and Daily Natural Gas minibuses, also in a Special Edition Metallica livery, provided a shuttle
service for the band’s crew during the concerts. These “green” vehicles contributed to Metallica’s goal of reducing their carbon footprint one concert at a time for a sustainable show experience and will. In addition, a ‘Truckers Contest’ has been created to engage truck drivers, inviting them to submit videos of themselves, regardless of their vehicle brand, while performing to the music of Metallica for a chance to win concert tickets.
A partnership for a better future IVECO and Metallica share a strong focus on environmental protection and social responsibility. IVECO is known for its commitment to “green” transport through long-standing investments in alternative propulsion solutions. As part of Iveco Group, the brand has committed to reaching net zero carbon by 2040 and will continue to support communities impacted by natural disasters and war, run training programmes for vulnerable youth and donate to feed people in need. These programmes align remarkably with the initiatives of Metallica’s foundation, “All Within My Hands”, which supports local food banks while the band is on tour, runs the Metallica Scholars workforce education initiative in support of community colleges, and contributes where possible to disaster relief efforts. Two partners perfectly in tune for a better future.
Edited by AkzoNobel Powder Coatings
The new high-performance Interpon A5000 powder coatings range developed by AkzoNobel provides an excellent corrosion protection and a durable finish for commercial vehicles.
AkzoNobel has launched the Interpon A5000 range of powder coating to give reliable, consistent and long-lasting protection to commercial vehicles for original equipment manufacturers (OEMs) and suppliers looking to combine performance with sustainability.
Interpon A5000 is a range of powder coatings for the chassis, body, and multiple parts of a commercial vehicle that addresses a series of customer needs. It delivers optimum levels of corrosion protection in challenging environments, with a durable finish in a choice of colours that last longer, protecting a manufacturer’s brand reputation. It is a
product that OEMs can also trust to be consistent worldwide, thanks to AkzoNobel’s global manufacturing footprint.
From trucks and trailers to buses and specialty vehicles, commercial vehicles need powder coating solutions that are as robust as the parts they protect. The full range comprises not only primers but also topcoats and clearcoats, and coatings that are designed to withstand multiple challenges.
These include damage caused by corrosion and UV light, or through chemicals like petrol, diesel, oil and other chemicals.
Commercial vehicle manufacturers are also looking for solutions that support their sustainability agenda, that reduce their energy consumption, carbon emissions and cost. To this end, the range is designed with sustainability in mind. The powder coatings are easy to apply for a right first-time finish that accelerates production volumes and avoids the need for costly re-working.
The range also includes products with lower curing temperatures, further reducing processing times, energy consumption and waste while delivering consistently high levels of performance and quality. And being powder coatings, they are free from Volatile Organic Compounds and generate almost zero waste, since any overspray can be recycled and reused.
Central to the range is the Interpon A5500 powder coating, a smooth primer that is ideally suited for use on the body of truck cabs, front grills, and bumpers. The primer is more sustainable than ‘traditional’ alternatives, thanks to the absence of any VOCs and flexibility in the coating process. It serves as the perfect basecoat not only for powders, but also for a liquid topcoat, enabling manufacturers to harness the benefits of both coatings.
Martina Lösgen, Global Segment and Key Account Manager ACE and CV says: “Interpon A5000 range is trusted by many of the major OEMs and fabricators for their reliability and performance, but also for the flexibility and efficiency that they can bring to their operations. Partnering with us enables manufacturers to add world-leading protection, color and finish to their world-class vehicles and parts.” To complement the range, AkzoNobel also delivers world-leading technical support services to help OEMs and their suppliers optimize their powder coating application lines, and the performance of the Interpon solutions they choose.
Other products within the range include Interpon A5150, which is ideal for delivering high levels of durability and corrosion resistance for trucks, trailers, and buses, and meets OEM surface friction standards; and Interpon A5160 which has all of the benefits of A5150 but with further improved UV light resistant. Specific powder coatings have also been developed for components like pressure containers and fuel tanks, including Interpon A5250, which resists petrol, diesel, oil,
chemicals, and weathering, and Interpon A5260, designed for pressure tanks with high resistance to road debris and excellent gloss retention. For the body parts and cabs, the range includes Interpon A5550, which is a full powder coating system and Interpon A5552 and Interpon A5554 which are specifically designed to balance Class A surface condition with an optimized cost per unit. The latter has superior levels of UV-durability for premium truck builders and other vehicles which require the highest quality finish. The range also includes Interpon A5560, a high quality clearcoat, and Interpon Redox, a series of primers that provide customers with a one-stop-shop for corrosion protection, even in the most challenging environments (up to C5 corrosive environments).
Ilaria Paolomelo ipcm®
With a view to sustainability and aiming to access new markets where toxic-free coatings are a must, the well-established contract coater ZD Group has recently implemented the tin-free coatings developed by Sherwin-Williams into its cataphoresis process. This choice reinforces its commitment to sustainable technologies without compromising the quality of its end results while unlocking new opportunities for growth in new markets and industries.
Strategic partnerships are a key lever for the success of any company, especially those starting as small family businesses and aspiring to grow into benchmark businesses in their sector. In the field of metal coating and surface treatment, collaboration with trusted suppliers is crucial to access advanced technologies and stateof-the-art chemicals and, at the same time, more sustainable but still high-quality finishes, thus responding effectively to growing market demands for higher performance and environmental friendliness of production processes.
However, the importance of partnerships goes beyond the mere technological aspects:
it extends to the human factor, including the provider’s reliability and level of technical assistance. For a company, being able to count on suppliers that not only sell products but also offer consistently attentive and customised support can be a huge added value. An example of this is the partnership that ZD Group, a company based in Padua (Italy) specialising in contract coating services for different industrial sectors, including ACE, automotive, and furniture, recently entered into with coating manufacturer SherwinWilliams (Bologna, Italy).
This was selected by the company for the supply of tin-free paints for its cataphoresis process, as well as Qualicoat Class 1 and
2 powders for components needing to be coated.
Three production hubs to meet all coating needs
ZD Group Srl began its journey in the world of metal coating in 2004. Founded as a small family business in Borgo Veneto (Italy), driven by courage, passion, and a constant commitment to innovation, it has grown rapidly and earned the trust of a network of customers throughout the Veneto region.
Riccardo Zanellato, its founder and current General Manager, recalls the company’s beginnings: “We started with a small powder plant in Santa Margherita d’Adige (Padua), working synergically with an external company specialising in galvanising processes to provide our customers with complete corrosion protection for their products.” Its dedication and willingness to continuously upgrade its technologies have transformed ZD Group into a benchmark metal treatment and finishing company. Today, it offers multiple services characterised by reliability, professionalism, and adherence to delivery times.
“ZD Group currently has three factories. The first, located in Santa Margherita d’Adige, specialises in the automated powder coating of small workpieces. The second, opened in Ospedaletto Euganeo (Padua) during the pandemic period, covers an area of 3,000 m2 and deals with the cataphoretic and powder coating of medium-sized components. The third, located in Este (Padua), is dedicated to treating heavy metal fabrications through a plant handling parts up to 5.5 metres and a static line coating components up to 8 metres in length.
photo: Cataphoresis + powder coated components for the ACE sector.
On the left: An example of the parts treated by ZD Group.
“We are also about to install a new liquid coating booth at our Ospedaletto Euganeo site,” adds Zanellato. “This will allow us to respond even more flexibly to the needs of customers requiring both functional and cosmetic finishes, such as the designer components we have recently treated for a prestigious hotel in Saudi Arabia.”
Cataphoresis + powder coating: an increasingly popular choice in the manufacturing industry
The production hub in Ospedaletto Euganeo is one of ZD Group’s most innovative facilities, designed to process medium-sized components with advanced finishing quality, especially in terms of outdoor resistance. Inaugurated during the pandemic, this site is equipped with a cataphoresis coating line and a powder coating plant. Cataphoresis is essential for sectors requiring maximum corrosion protection, including the ACE sector, whose products are subject to weathering and chemical and mechanical attack throughout their life cycle,” states ZD Group’s General Manager.
The line complies with the European Directives for the automotive, industrial, and off-road vehicle and electrical/electronic equipment sectors, and its treatment cycle includes as follows:
Shot blasting on request to remove impurities from laser cutting operations.
Degreasing with chemicals supplied by Condoroil (Casale Litta, Varese, Italy).
Two rinses with mains water.
Nanotechnology passivation.
One rinse with demineralised water.
Application of a tin-free epoxy cataphoresis coating developed by Sherwin-Williams.
One rinse with ultrafiltrate and demineralised water.
Oven-drying at 200 °C.
“The deposited cataphoresis film has an average thickness of 18-30 mm and a salt spray resistance of up to 500 hours under ISO and ASTM standards. The product’s chemical-physical characteristics ensure excellent adhesion and impact resistance. In addition, at this site, we can apply epoxy, polyester, polyurethane, and acrylic powder coatings after cataphoresis, adapting our cycle to each customer’s requirements to meet the most diverse aesthetic and functional needs,” says Riccardo Zanellato.
Indeed, ZD Group’s Ospedaletto Euganeo plant is also equipped with a powder coating plant that allows for the rapid application of several coats without multiple passes within the line: after the application of a powder primer in the booth, the process continues with a hot air gelation oven, the application of a finishing coat, and finally the complete curing of the two layers.
The plant is also equipped with a Lesta articulated robot assisting the operators in handling large production volumes, thus improving efficiency and ensuring greater accuracy.
“Currently, this plant operates in two shifts, and each process step is tracked and monitored to gather detailed information. Depending on specific customer requirements, we can therefore carry out a cycle including pre-treatment and cataphoresis, one with pre-treatment followed by the application of one or more coats of powder, or one combining the two processes, with cataphoresis first and then powder coating,” illustrates Zanellato.
Making cataphoresis more sustainable
To optimise its cataphoresis process and reduce its environmental impact, ZD Group recently turned to a new supplier of coating
products: Sherwin-Williams. “Initially, it provided us with a standard new-generation epoxy product that still had a tin-based catalyst. In the meantime, in its laboratories in Minneapolis (Minnesota, USA), it developed a platform that uses a tin-free catalyst to reduce its environmental impact and make the resulting coating compliant with the NSF/ANSI/CAN 61 - Drinking Water System Components Health Effects directives,” says Zanellato.
From left to right:
The cataphoresis tank.
The overhead crane for workpiece immersion.
The plant dedicated to large-sized components.
“This new tin-free catalyst is perfectly compatible with the existing cataphoresis system, and no changes to the base polymer were required. This has allowed ZD Group to continue using the same electrophoresis tank, feeding it with the new product, thus achieving an economic as well as an ecological advantage. ZD Group began using the new product in September and found that cross-linking temperatures and operating conditions remained unchanged. In practice, switching to this new solution was simple: all that was needed was to replace the catalyst, obtaining a paint that was just as effective but safer and more environmentally friendly. The chemical-physical-mechanical resistance and cross-linking performance remained the same, without any alteration in the quality of the end product,” states Stefano Caminati, the head of Sherwin-Williams’ Minerbio laboratory.
A significant advantage offered by tin-free paints is their hazard-free label, which enables ZD Group to store large quantities of product without being subject to hazardous material restrictions and gives it the opportunity to enter new sectors, such as the food industry, where the absence of heavy metals in formulations is of the essence. “We also collaborate with Sherwin-Williams for the supply of powder finishes, although not exclusively because we work to specifications, so our customers often choose the finish to be used. Primarily, we use epoxy-
polyester hybrid powders or super durable industrial and architectural polyesters, with a Qualicoat Class 1 or 2 certification,” indicates Zanellato.
The collaboration with Sherwin-Williams brought numerous strategic advantages to ZD Group, consolidating their relationship of trust and opening up new market opportunities. Two main aspects emerged as key benefits: on the one hand, the consistently reliable technical assistance offered by Sherwin-Williams, which stands out for its helpfulness but also in-depth product knowledge, and on the other hand, the expansion of the markets that ZD Group can access by using low environmental impact coatings, ideal for finishing products that require the absence of heavy metals: this has enabled the company to obtain new approvals in markets where the absence of blacklisted components in the applied coatings is a critical requirement.
“Moreover, Sherwin-Williams’ technicians are always on-site, ready to devote even entire working days to thoroughly checking every detail, something we consider to be a fundamental added value, far more important than economic aspects. We also share a WhatsApp chat with the technical sales engineers who follow us, ensuring real-time support
even at weekends. In addition, our company uses Sherwin-Williams’ laboratories to carry out advanced tests, such as salt spray tests and analyses on pre-treatment chemicals, to ensure consistent product quality in terms of corrosion resistance. Finally, another key characteristic of this partnership is that Sherwin-Williams offers training opportunities to each new customer so they can fully understand the products’ features and allow their operators to gain the necessary confidence in managing the process. This approach also enables us to identify any problems, such as faulty film distension or crater formation, early on and intervene promptly through phone support by Sherwin-Williams’ technicians,” notes Zanellato.
Powder-coating ACE components: the Este site
ZD Group’s main target market is the agricultural, construction, and earthmoving (ACE) machinery sector. For this regard, it exclusively employs an automatic coating system handling heavy metal fabrications and large items up to 5.5 metres in length that has been designed by Linea Eco Air (Sona, Verona, Italy). The system operates in a stepwise manner, with an automatic door opening and closing system. The cycle starts with the pre-treatment of parts in a two-stage tunnel. The first stage is degreasing with a high-quality product, FIPROPHOS 510, to remove oils and contaminants from the metal surfaces; in the second stage, the components are rinsed with demineralised water, using FIPROPLUS 707 as an additive to improve the operation’s effectiveness on rougher metals. After pre-treatment, the parts are inspected to ensure they are completely degreased and ready to be coated. The two-rail conveyor is equipped with load bars supporting workpieces weighing up to 1,500 kg.
“When the workpiece is in the pretreatment tunnel, both during the degreasing and rinsing phases, a pneumatic cylinder moves the load bar back and forth over a distance of 400 mm. This motion ensures that the piece is fully covered by water, allowing for uniform cleaning. This mechanism reduces the number of spraying ramps needed for cleaning, resulting in significant savings in electricity and fuel,” explains Gianfranco Soliani, the owner of Linea Eco Air. “Additionally, the rinsing phase, which lasts one minute, is carried out in the same area designated for drying, saving approximately 7 meters in occupied space.”
“The forced convection drying oven features a system that circulates air through side slits and optimal thermal insulation to guarantee high energy efficiency. A methane gas air stream burner reduces pollutant emissions and improves the plant’s efficiency. Thanks to its innovative design, this burner does not require an exhaust chimney for combustion fumes, ensuring savings of up to 40% compared to other heating systems,” Soliani adds.
with a complete service that includes system design manufacturing, installation, technical support and chemicals
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 next step is the application of powder paint in an automatic booth located within a heated, pressurized room made of plastic material. This is equipped with six guns supplied by Wagner (Valmadrera, Lecco, Italy) and has a powder extraction and recovery system that guarantees a 97-98% efficiency.”
The booth has a special feature: two manual touch-up stations outside the enclosed automatic coating area. This gives the operator an advantage in terms of both paint application and freedom of movement, promoting safe working conditions. The coating process is completed with the parts passing through the curing oven. Afterwards, the components dwell in a cooling tunnel with an airflow at room temperature, ensuring uniform cooling. The whole process is automated thanks to a PLC that manages all cycle phases and offers real-time monitoring of all process parameters, guaranteeing consistent quality and total control over production.
A solid company that has made operational flexibility its main strength
With twenty years of history behind it, ZD Group is a multifaceted company approaching the contract coating sector from several sides, thus offering combined coating cycles that are always custom-designed
to meet any performance requirement while striking the right balance between costs and each customer’s actual needs. Equipping itself with several plants to offer different coating processes and, above all, handle parts in various sizes was ZD Group’s first step on this path to operational flexibility. Forming a partnership with multinational company Sherwin-Williams for the supply of paint products, on the other hand, was the step that enabled it to grow technically and identify the best strategies to make its business more sustainable.
Demo Serbatoi produces tanks for storing and transporting diesel fuel for agriculture, as well as tanks for the oil, industrial, and pharmaceutical sectors.
SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES
Monica Fumagalli ipcm®
One of the most challenging fields of application for paint manufacturers is that of storage tanks, as these containers require protection against both the weather that attacks them externally and the chemicals inside them. Mirodur, a producer of industrial and protective coatings, has won the trust of one of the giants in this sector, Italian company Demo Serbatoi, thanks to its products’ high quality and performance but also its foresight, enabling to anticipate customer needs with formulations developed with a view to future enhancement.
Storage tanks in contact with chemicals of different kinds, from fuels and water to liquid foodstuffs and pharmaceuticals, must comply with specific safety and environmental protection standards and, therefore, be made in corrosion-resistant materials such as steel or reinforced plastic and double-walled to prevent accidental leaks or spills. Their capacities range from small mobile tanks (200-500
litres) to large fixed tanks holding several thousand litres. Their exposure to degrading agents is twofold: they must be able to withstand, on the one hand, atmospheric agents such as rain, sun, snow, and temperature fluctuations and, on the other hand, chemicals stored in both liquid and vapour form. Choosing a suitable coating is therefore crucial to ensure their functionality and durability.
Demo Serbatoi (Cellino Attanasio, Teramo, Italy), now a brand owned by Fuel Solution S.r.l., was founded in 1991 and started its activity with a line of storage tanks mainly for the agricultural sector. Over time, it expanded its production by adapting to the needs of national and international markets, gradually integrating advanced technological systems. “We aim to maintain a high standard of quality,” explains Federico Sabella, the Chief Operating Officer of this Abruzzo-based firm, “by using premium materials and specialised technicians who are very driven and feel a strong sense of belonging in our company.
Demo Serbatoi’s young spirit, its ability to combine tradition and innovation, and its dynamism and adaptability make it the ideal partner for designing, manufacturing, and installing storage tanks that meet high quality and production standards. This is one of the reasons why working with coating manufacturers specialising in this industry – like our partner of choice, Mirodur Spa (Aprilia, Latina, Italy) – is an additional guarantee of customer satisfaction.”
Demo Serbatoi’s multiple production lines
In addition to its line of tanks for storing and transporting diesel for agriculture, Demo Serbatoi also manufactures products for the oil, industrial, and pharmaceutical sectors and plans to develop a range for storing water for firefighting use, a very promising market. “Our core business,” confirms Sabella, “is the production of fuel storage and dispensing tanks approved by our Ministry of the Interior, both in
one-chamber versions with a 110% containment basin and in vertical two-chamber versions, in compliance with Italy’s Ministerial Decree of 22/11/20171. We also produce containerised refuelling systems complete with professional dispensing columns, UN-marked and ADR-approved2 tanks for the transport of fuel by road in steel and, more recently, polyethylene, tanks for service stations for private and commercial use, two-chamber tanks complying with EN 12285, AISI 304 and AISI 316L stainless steel tanks for industrial plants and highpressure equipment, compressed air tanks, accumulators, hot water storage tanks, and steam manifolds built in accordance with Directive 2014/68/EU (PED). Finally, we are expanding our production line for industrial and firefighting water storage tanks complying with EN 12845.”
Over the last few years, Demo Serbatoi has invested in insourcing several processes, also successfully entering foreign markets with its ‘just in time’ solutions. “Our company,” Sabella emphasises, “can offer design, development, and construction services in compliance with the main international standards. This is possible thanks to our technical R&D department and, where necessary, selected external engineering
1 https://www.gazzettaufficiale.it/eli/id/2017/12/06/17A08114/SG
2 ADR is an international agreement between countries of the United Nations Organisation whose purpose is to harmonise safety standards for the international carriage of goods by road and ensure an acceptable level of safety for such transport. https:// unece.org/about-adr
From top counterclockwise:
Raw components before the coating operation.
The application of the DTM paint product supplied by Mirodur.
The manual application phase.
services capable of developing projects in compliance with the main directives and calculation codes. Our welding procedures and personnel are qualified according to European and/or American standards. Suitably trained and qualified internal or external staff tests our products. In the case of PED equipment or pressure vessels designed to contain fluids (liquids, gases, or vapours) at a pressure other than atmospheric pressure, which are distinguished by risk category, we carry out the entire process in cooperation with internationally accredited bodies.”
In the storage tank manufacturing industry, certifications are indeed crucial and play a vital role in several aspects, including safety, reliability, regulatory compliance, and market competitiveness. “In addition to quality certification according to ISO 9001:2015, Demo Serbatoi is certified for the manufacture of structural components and kits for steel structures (execution class EXC3, method 3a) under EN 1090-1:2009+A1:2011, including relevant welding processes and procedures. It is also UL and ULC certified in compliance with UL 142 and ULC S601 for constructing steel above-ground tanks for flammable and combustible liquids for the US and Canada. Finally, it uses strict in-house procedures for controlling and managing its manufacturing processes from raw material procurement to assembly.”
Currently, the company has three separate departments for production, assembly, and storage. Each department is managed autonomously but with the help of a single monitoring system to guarantee quality, continuity, and reliable delivery times. All production steps take place in-house, starting with the raw materials, i.e. metal sheets and dished ends. “We begin by bending the metal sheets to obtain the cylindrical bodies that will form our tanks. Dimensions can vary from the smallest standard 1,200-litre products, with a
footprint of 1.20 x 2.10 x 1.20 m, to the largest 9,000-litre products, with a footprint of 2.20 x 4.10 m and a height of well over 2 m. For fuel and firefighting tanks in both underground and above-ground versions, we can achieve larger dimensions (3-3.5 m in diameter and up to 16-18 m in length), as our department is structured to even build 150 m3 tanks in one piece. To ensure the constant development of our production of ‘special-order’ tanks, i.e. built to specific technical requirements and/or plant needs, whether small or large, we have decided to invest in our welding department by doubling the line handling these products. This will also guarantee shorter delivery times.”
After machining and assembly, the tanks undergo a manual degreasing step and are then taken to the coating booth. “Each structure is led into the chamber where the operator manually applies a primer and a top coat with an airless pump,” illustrates Sabella, “which allows for fast application and, ultimately, increased production capacity. Depending on the size of the tanks, we can paint up to 4 structures at the same time, coating an average of 20 tanks per day. Our standard process includes the application of one coat of primer and one coat of finish. Underground tanks are obviously an exception due to the harsh conditions they are subjected to: in this case, we follow other construction standards requiring more complex treatments, such as the application of epoxy and fibreglass on the external surfaces and possibly anti-corrosion treatments on the internal ones, depending on the products stored inside the vessels. Our customers’ stringent specifications can require thicknesses of up to 250 µm and, in rare cases, even more. That calls for redefining our cycle and the type of coatings used, which, in turn, means we need to constantly keep our supplier Mirodur in the loop.”
“The paint products we supply to Demo Serbatoi are the result of formulations specifically designed for the tank sector, which has become a significant field for Mirodur,” says Riccardo Vitelli, Sales Manager at this Lazio-based company. “The development of such coatings began in our laboratories to meet the requirements of a long-standing vessel manufacturer, active since the 1950s, which was located near our first site in the outskirts of Rome. The same happened with a gas storage tank manufacturer located near our plant in Pomezia (Rome), which was then replaced by the current one in Aprilia. Such geographical proximity allowed us to get to know these businesses very well and thus specialise in this industry, developing specific products whose main characteristic is the possibility of achieving high thicknesses and which we provide to certain customers in the DTM version, i.e. applicable on metal in one coat.”
Eurotherm solves every problem concerning painting processes, creating complete lines for the entire process.
Our structure is organized and flexible and able to satisfy the most demanding requests. Customers who turn to Eurotherm are customers who, despite knowing the “painting process”, want to improve production by adopting highly customized technical solutions.
in Turin (IT) Headquarter
95 Employees 205 Plants realized in 2023
Eurotherm S.p.A.
T +39 011 98 23 500 | M info@eurotherm.eu
Eurotherm France S.A.S.
T +33 6 76 72 48 65 | M france@eurotherm.eu
Eurotherm Oberflächentechnik GmbH
T +49 7571 92795 10 | M germany@eurotherm.eu
Eurotherm Benelux Srl
T +33 6 47 44 96 27 | M dekergorlay@eurotherm.eu
Technical characteristics of Mirodur coatings
Mirodur supplies Demo Serbatoi with primers and top coats based on the different characteristics of the tanks to be treated. “When high corrosion resistance is not required,” Vitelli emphasises, “we supply an acrylic primer that uses the same hardener as the top coat, thus allowing for a wet-on-wet application operation that ensures faster and more consistent results. In the case of stricter demands in terms of corrosion protection, we have formulated a zinc-rich epoxy primer that can be applied directly on the metal sheets, with the possibility of achieving high thicknesses to guarantee optimum corrosion resistance. These products contain adhesion promoters that enhance their barrier effect, a key factor for salt spray resistance: according to our studies, adhesion reduces blistering substantially.”
Production continuity guaranteed by the paint manufacturer
“Our first contact with Mirodur dates back to a request for a special paint product for some tanks intended for a military base,” Sabella recalls. “Thanks to their sales agent in our area, we discovered it as a supplier of coatings approved to military specifications: exactly what we needed at that time. We were impressed by its team’s professionalism, and when it came to looking for better-performing products for coating our tanks, we decided to conduct some tests with those formulated by Mirodur. They convinced us in terms of both thickness and visual impact, as well as final coating performance.”
“Compared to our standard product supply, we have recently corrected our formulation to meet this customer’s requirements,” explains Vitelli. “Within our portfolio of matte, gloss, and semi-gloss finishes, Demo Serbatoi favours high-gloss ones. Originally, our standard formulation was semi-gloss. We have improved it for better flexibility so that, should our customer request it, we can immediately supply it with the required product without stopping its operations due to the long lead times needed to modify our formulations. In future, we would also like to further develop water-based coatings in cooperation with this important player in the storage tank sector.”
“In addition to its products’ quality, the attention Mirodur devotes to us to guarantee our production continuity further confirms we have chosen the right supplier,” Sabella concludes.
Anodizing & Powder coating plant realization
Waste Water Treatment Plant
Chemicals for Waster water treatment
A French manufacturer has achieved a 90% level of automation in the coating of tractor front loaders thanks to the powder coating solution designed and installed by WAGNER.
For decades, a French agricultural machinery manufacturer has been simplifying the daily work of farmers with cutting-edge equipment, including its innovative and reliable front loaders for tractors.
Until 2022, the swing arms and buckets of the front loaders were primed by dip coating.
Components with complex geometries were then manually powder-coated and cured in an oven. This production process had several significant drawbacks.
Depending on the shape of the part and the operators’ experience, the high percentage of manual work could lead to inconsistent coating quality and significantly slow down production
speed. A high level of manual labour also means the company is heavily dependent on skilled and experienced staff. Moreover, the dip coating process releases VOCs (Volatile Organic Compounds), which can be harmful to health and the environment. The company was aware of these drawbacks and, in order to increase its competitiveness and maintain its market leadership, decided to take action.
For the new project, several key requirements were established, including:
85% automation to achieve the ROI target;
VOC-free coating;
Reduction in rework;
Increased production capacity;
More efficient use of coating materials.
The advantages of the WAGNER solution
Faced with the benefits of the high-level coating solution from WAGNER, the French company chose to collaborate with the German partner for several reasons.
First, because they were convinced by the lab test results, which outperformed those of the competition. Secondly, for the guaranteed automation level of 90%, which exceeded the value initially set for the ROI target.
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
Lastly, for WAGNER’s extensive experience in the agricultural and construction machinery sectors, which includes important clients.
The coating solution designed and installed by WAGNER has led to a significant increase in production efficiency.
The company has now replaced dip and manual powder coating with a fully automated system.
Thanks to 3D coating, it is possible to scan geometrically complex parts as they enter the coating booth. This allows the powder guns to automatically adjust to the part’s geometry. The result is high surface coverage with minimal powder consumption and optimized system usage. S-Cube booths were installed for both stages of work – primer and topcoat – as they allow for maximum automation and are ideally designed for particularly large and complex parts.
The SuperCenter EVO powder centre ensures quick colour changes with a high level of automation.
Thanks to the latest generation of WAGNER powder centres, the company is able to continuously record and optimize a wide range of production data, including powder consumption.
The results speak for themselves
The new WAGNER solution has delivered:
90% automation, exceeding the ROI target;
An 80% reduction in manual labour;
An over 40% increase in production capacity;
A primer without VOCs, that are harmful to health and the environment;
A significant increase in coating material consumption efficiency.
Edited by GSB International e.V Düsseldorf, Germany
GSB International e.V has published a research project aiming to better understand how to pretreat and coat 3D-printed components for aluminium facades.
Everyone is talking about 3D printing. Meanwhile, there are numerous applications for 3D printing – with a wide variety of substrates. In 2019/2020, the topic was frequently mentioned to GSB, in its position as a quality association for the coating of aluminium and steel1. At that time, 3D printing of aluminium was not yet of great relevance in the construction sector. Plastics were usually the material of choice. However, from this moment on, 3D printing ended up in the aluminium quality committee’s idea backlog. Almost five years later, the time had come. 3D printing was also picking up momentum in the sphere of GSB involvement. Start-ups and established companies began to expand their activities in the field of 3D printing of aluminium parts used for facade construction.
1 Mader, P. (2019). Innovative Growth Opportunities for an Industrial AssociationOpportunity Recognition using the Granularity Approach in the Market for Coating Aluminium and Steel Components in the Case of GSB International e. V. [Not published]
At this point, no clear trend can yet be seen as to where the journey will lead and whether the topic will find widespread appeal in the market. The production of the components is still very expensive and there are legal restrictions. When it comes to aluminium in the construction industry, only alloys that have good corrosion resistance without the protection of a coating may be used2. This is simply a safety measure. The alloys typically used for profiles are EN AW6060 T 66 [AlMgSi] or EN AW-6063 T 6 respectively T 66 [AlMg0.7Si]. For sheets, it is typically AW-5005a H 24 [AlMg1(B)]. For this reason, profiles and sheets made of those alloys mentioned are also used by the GSB for corrosion tests on coated aluminium.
2 Mader, W. (2020). Sekundäraluminium und Rezyklatgehalt im Bauwesen. Internal information sheet of Aluminium Deutschland, formerly GDA.
However, other alloys are typically used for 3D printing. Alloys that are well known in the casting industry. Typically, AlSi10Mg is used. Only very few casting alloys are permitted for load-bearing components. If the composition complies with EN AC-43000 [AlSi10Mg(a)], for this alloy, only the casting process with permanent mould is suitable if load-bearing components are to be produced3
Special permits must therefore be obtained for construction projects in which 3D-printed components made of such an alloy are used. Intensive research was carried out and it was found that although there are many projects involving the 3D printing of components for aluminium facades, nothing could be found on the subject of coating these components. For this reason, an initial pilot test was started. 3D-printed aluminium sheets were obtained from two manufacturers, here referred to as manufacturer A (Fig. 1) and manufacturer B (Fig. 2). The sheets were acquired both as raw material from manufacturers A and B and in a mechanically processed version. Different mechanical processing methods were used for the latter type. The sheets from manufacturer A were blasted (Fig. 3) and the sheets from manufacturer B were ground (Fig. 4). The sheets were then pretreated in accordance with GSB Quality Regulations (GSB-certified chromium-free pretreatment) and coated with a GSB-approved coating powder. It was noticeable that the surface of the raw sheets was very grainy. Both the blasted and the ground surface were significantly smoother.
3 Eurocode 9: EN 1999-1-1: Design of aluminium structures - Part 1-1: General rules, 2023
The cross-cut test according to ISO 2409 and the boil test according to GSB were carried out on all sheets. The cross-cut test was carried out before and after the boil test. All the sheets passed these tests. Furthermore, a 1000-hour filiform corrosion test according to ISO 4623-2 was carried out and the GSB evaluation method was used. Here, the maximum thread length (< 2 mm) and a filiform corrosion factor are used, which is calculated from the average thread length multiplied by the thread frequency (< 0.3 )4. Two of each sheet metal types were put into the filiform corrosion test. The blasted and the ground sheets failed the test. The values were significantly higher than GSB certification requires. However, the raw sheets of both manufacturers passed the filiform corrosion test of the GSB without any problems. Testing conditions applied here for the assessment are normally applied for components that are used in environments that can be characterised by the corrosivity category C4.
The difference between raw (Fig. 5), that passed the corrosion test, and mechanically processed (Fig. 6), which failed the corrosion test, was the same for all test sheets. The unverified assumption was therefore that the coating interlocks with the raw, rough surface, thus achieving better results in the corrosion tests.
For this reason, an attempt was initially made to carry out a GDOES analysis.
4 GSB International e.V. (2023). GSB AL 631-1. International Quality Regulations for the Coating of Building Components. Available for download at: https://gsb-international.de/en/quality-regulations/
However, this could not be carried out for one of the sheets in particular due to the roughness of the surface (a vacuum could not be created). Consequently, a WDXRF analysis was carried out. The results were so heterogeneous that no clear differences could be identified which could explain the poor corrosion test results of the mechanically processed sheets. Thus, the hypothesis can be extended by the possibility that the alloy itself is less suitable for coating, but that this disadvantage in terms of the alloy itself may be compensated by the rough surface of the 3D-printed components in their unprocessed state. In addition to the test results, it was observed that the rough structure of the component could still be seen through the coating. This gave the impression of a textured coating, even though no textured coating was used. Even with the sheets processed mechanically (blasted or ground) before the chemical pre-treatment process, an irregular structure was still visible after coating.
The pilot test then showed that there is a significant negative impact in the results of the filiform corrosion tests when 3D printed components are blasted or ground before the normal chromium-free pre-treatment process. However, further research is needed to clarify the exact reasons for this. If the components are left untreated, good results can be achieved in filiform corrosion tests with a chromium-free pretreatment. It is also to be expected that the structure of the material will continue to show through in 3D printed components and that the effect of a textured coating will be created in the case of a smooth material system.
Further research is needed to see whether the structural appearance can be eliminated with 2-layer systems and to see what effect this would have on corrosion protection.
It is not yet certain whether 3D printing for aluminium will become established throughout the construction sector, but there is certainly enough time to conduct follow-up research.
To conclude this article, the Quality Committee Aluminum of the GSB International would like to take this opportunity to thank both the NABU Oberflächentechnik and the fem Forschungsinstitut for their active support in carrying out the project.
Online Tool for your 3D Surface Configuration With the TIGERator, you can find the perfect powder coating finish for your project in a matter of seconds! This innovative online solution offers a realistic preview of a wide range of TIGER Drylac® powder finishes on selected 3D models, bringing your visions to life with just one click – easily and browser-based on your desktop, smartphone or tablet.
Monica Fumagalli ipcm®
With a coating system installed just a few months ago, Movinter (Savona, Italy), a manufacturer of components for rolling stock, has obtained approval for its coating cycles from some of the most important players in the railway sector. Its staff’s technical expertise and its partnership with a supplier specialising in railway transport coating systems, Eurotherm (Volpiano, Turin, Italy), have equally contributed to this success.
The European Green Deal stipulates that transport must reduce CO2 emissions by 55% by 2030 and 90% by 2050. The railway sector is affected both directly, with its goal of decarbonisation within the required timeframe, and indirectly, because the reduction in emissions will lead to a decrease in road transport in favour of transport by rail, which is more sustainable if only in terms of the amount of goods and people that it can move at the same time. Indeed, the European
Commission’s strategy includes doubling high-speed rail traffic by 2030 and tripling it by 2050, with the aim of completing its core network and the global TEN-T network to create a single European transport area characterised by one comprehensive, integrated, and multimodal transEuropean network covering land, sea, and air transport, encompassing and connecting all EU member states in an intermodal and interoperable manner.
This European plan has had and will continue to have a major impact on the players in the railway industry and its linked sectors, a market continually growing and, at the same time, affected by the latest trends related to digitalisation and sustainability.
To understand how the delicate process phase of the surface treatment of rolling stock and railway components can contribute to such developments, we visited Movinter S.p.a. in Cairo Montenotte (Savona, Italy) and talked with its technical staff and CEO Simone Lo Giudice. This company – which had already restored its production capacity before our visit, just two days after the severe flooding that hit the Bormida Valley area, causing serious damage to homes, shops, and factories – boasts thirty years of experience in the supply of railway components, i.e. light and heavy metal fabrications and piping, but also in plant engineering and maintenance.
Lo Giudice explains that Movinter chose to invest in human resources and technological innovation, also driven by the new company management initiated by the industrial holding company listed on the Milan Stock
Exchange, RedFish LongTerm Capital S.p.A., which acquired it in April 2023: “Thanks to its know-how, Movinter is a well-established benchmark supplier in the railway sector, especially of complex light-weight metal fabrications and piping assemblies, manufactured according to the specific requirements of each customer. We specialise in handling large orders, thanks to our high-level expertise that makes us competitive in this challenging and complex market and our extreme reliability. We can offer a service of excellence because we consistently invest in the certification of our strengths, in the development of professional skills, and in technology to guarantee the safety and verification of our processes. Today, we can also count on state-of-the-art management software to ensure maximum production and logistics efficiency with reduced warehouse requirements.”
When the share acquisition by the Milanese holding company was finalised in April 2023, Movinter had already initiated a project for insourcing its coating operations with a line designed and manufactured by Eurotherm Spa (Volpiano, Turin, Italy).
“It was a long-term insourcing plan,” explains Dario Chiaramonti, Group Quality Manager, “which also involved the pickling phase, and in which our previous owners had decided to invest mainly to solve some critical issues related to the handling of our components. We treat parts with small to medium sizes but different shapes and characteristics, produced in large batches of up to 20,000 pieces per month, and there was a high risk of damage during their long journeys to reach the sites of our coating contractors certified for the railway sector, located throughout Italy.”
Movinter’s story: from glassworks to the acquisition by RedFish LTC
Founded in the mid-1980s by brothers Vito and Stanislao Sambin, Movinter began its activity in the glassworks sector before moving into the railway industry ten years later, which accounts for around 95% of its production today. The production area covers an area of 36,000 m2, of which 17,000 m2 are covered. Movinter is among the first companies chosen by the most important players in the national railway sector,
including Alstom Ferroviaria, Hitachi Rail Italy and Titagarh Firema, but also the international one for the supply of both internal and external components for assembly with rolling stock.
“RedFish LongTerm Capital,” indicates Lo Giudice, “is an industrial holding company with a long-term investment horizon. In April 2023, the company acquired 100% of the shares of Movinter. This acquisition offered RedFish LTC an important opportunity to enter a highly interesting European and global sector where Italy has always played a primary role, especially regarding the most critical engineering and production phases. Movinter is a key company in the province of Savona, and we want to contribute to its growth in terms of both employment capacity and market prestige.” The company is now part of a Group with a turnover of approximately 57 million Euros, which includes two other businesses: Six Italia Spa, which was acquired in February this year and is a major player in the fire protection and soundproofing market, with products manufactured for key railway and naval projects, and Saiep, which joined the group in June and specialises in designing, manufacturing, and installing control
and power cabling and electrical switchboards for the railway, power distribution, and automation sectors.
Metalworking processes of excellence
“Our technical department works exclusively based on customer drawings: we do not have a standard product catalogue, but we handle around 3,000 different components monthly,” states Piping Business Unit Manager & CTO Andrea Vaira. “We can produce small, medium, and large structural steelwork to high quality standards, using different materials such as stainless steel, aluminium alloys, Magnelis®, and carbon steel. Our metalwork area is divided into two different production units covering a total of 11,000 m2. One is the cutting and bending department dedicated to 2 to 4 mm-thick sheets, which houses modern bending, laser cutting, and punching machines and guarantees high flexibility and responsiveness; welding (TIG, MIG/MAG, and RW), clinching, and riveting are just some of the processes of excellence for which Movinter is recognised in the industry. The other division is dedicated to piping and
is equipped with state-of-the-art CNC bending machines and an optical control system; it performs machining operations on pipes with diameters ranging from 6 to 80 mm, made in stainless steel (95%), aluminium and copper alloys, or carbon steel.”
A custom-designed system for the most diverse components
Davis Gioielli, Movinter’s current Painting Manager, joined the company nine months ago: with the coating line just installed, he was tasked with testing it, starting production, training the team, and establishing the in-house machining processes needed to obtain cycle approval from major customers. “Thanks to my previous work experience, first in the automotive sector and then in the railway one, I was familiar with the advantages and peculiarities of Eurotherm’s systems, which are always characterised by great efficiency and flexibility. Getting involved in a project that was practically already completed was not easy. However, thanks to the fruitful collaboration of Eurotherm, a well-known system
provider in the railway sector, we now have a line that is perfectly suited to our needs for maximum versatility and can potentially be further expanded – in fact, we have a new project already in the planning stage. Moreover, Eurotherm’s technical team can intervene remotely at any time to solve any problem that may arise.”
The line starts with a shot blasting cabinet featuring a total grit recovery system with floor scrapers; the grit used can be of two types, in stainless steel and corundum, depending on the required roughness characteristics. There are two pressurised liquid coating booths: originally, one was intended for grinding operations, but it was soon converted into a second liquid booth to have two interchangeable machines. They are linked to a coating management unit supplied by Wagner and managed via an Intellimix mixing and dosing device, as well as to an 80 °C-drying oven. The line is complemented by an overhead conveyor equipped with 10 m load
bars with a maximum capacity of 1000 kg, two semi-automatic transfer carts for smaller parts, which account for 80% of production, and a lifting station for larger, bulkier components.
"The mixing process with the Wagner Intellimix Touch 2k system brings significant advantages in managing two-component painting, thanks to the system's flexibility for both small batches and high-volume production runs, even exceeding 200 pieces. It’s simply a matter of selecting the preset recipe - up to 99 recipes can be set - with the catalyst ratio specified on the paint's data sheet, and the system automatically starts, accurately proportioning and dosing the paint in the application phases," explains Mauro Casati, Area Manager of Liquid Coating at Wagner. "The Intellimix system continuously monitors and maintains the preset catalyst ratio, halting operations if there are any irregularities in the painting phase. Beyond ensuring correct catalysis, the automated system provides a considerable time savings. For
smaller batches, however, the company has chosen to continue with manual mixing by an operator. Thanks to the technical support of our Wagner Certified Partner BV COLOR, we are also able to ensure prompt and quality assistance,” adds Casati. Incidentally, as Gioielli points out, “Since Six Italia joined the Group, we have also started to paint components for the naval sector, and we hope to establish ourselves in this area as well with approved cycles.”
The development of the new project
“We generally apply one- or two-coat systems preceded by manual degreasing and masking, based on customer specifications and with thicknesses of up to 300 microns,” Gioielli adds. “The type of paint, i.e. liquid or powder, is also specified by our customers, depending on the components’ intended use, for example considering whether they are assembled in a visible or concealed area or placed inside or outside a wagon. We chose to install a system applying water- and solvent-based liquid paints because this is still the prevailing trend in the railway industry, even though powder coatings are becoming increasingly popular.
Let‘s talk about powder coating.
A technology that is proven since decades and actually, it‘s just getting started with FLOWSENSE. FLOWSENSE? It‘s a software masterpiece and a bunch of small sensors that do big things: Consistent powder output from the rst to the last workpiece. Reliability, measured in real time. Put quality on repeat!
© ipcm
The conveyor and, on the left, the drying oven.
© ipcm
The tintometric system a detail of a coated part.
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 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.
ROBOTISED PAINTING SYSTEMS
STANDARD AND CUSTOMISED RECIPROCATORS
AUTOMATIC FEEDING SYSTEMS FOR PAINTING PLANTS
Astrid Hinterholzer TIGER Coatings GmbH & Co. KG - Wels, Austria astrid.hinterholzer@tiger-coatings.com
In the dynamic world of CMF and industrial design, efficient decision-making and creative freedom are crucial to the success of a project. TIGER Digital Finishes (TDF) offer a pioneering solution for the digital visualisation of surfaces that not only saves time and resources, but also increases the quality of the design process.
The Austrian powder coating manufacturer TIGER provides over 1,500 digital finishes in the file formats .axf, .kmp and .ex, available for free download on their website. The files are based on real scans of original powder-coated surfaces with TIGER Drylac® and offer CMF and industrial designers or architects the unique opportunity to finish rendered objects with powder coating at a mouse click, for an appearance unrivalled for its realistic appearance. This allows colours, effects, gloss levels, and textures to be viewed in brilliant quality on the screen.
All it takes is a quick visit to the TIGER webshop (www.tiger-coatings. com/shop) to select the desired digital surfaces and download them with just a few clicks. The files are compatible with common CGI software such as KeyShot, Maxwell, AMD Radeon, NVIDIA Iray, Maya, VRED, AUTODESK, 3ds Max, Unity, OCEAN, ELSE Corp, SHOEMASTER and many more.
TIGER Digital Finishes offer significant benefits to designers by speeding up decision-making and enhancing creative processes. The ability to digitally select powder-coated finishes and immediately visualize them on a screen eliminates the need to wait for physical sample panels. Immediate availability also allows more time to be spent experimenting and coming up with creative ideas before a prototype is created. This strengthens the imagination of the people involved and minimises the risk of costly changes in later project phases. The digital focus of TDFs also contributes to sustainability, as fewer
sample panels need to be produced and sent out. However, it is important to emphasise that digital materials will not completely replace analogue sample panels in the future. At all times designers have the freedom to either work completely digitally, combine digital designs with a physical final selection or use only analogue samples.
TIGER Digital Finishes in the design process: insights from industrial designer Bernhard Kaliauer
The Austrian studio KID, founded by Bernhard Kaliauer, stands for sustainable product design that impresses with its precision and efficiency. Using state-of-the-art CAD modelling, high-quality prototyping and a deep understanding of design and manufacturing processes, the Linz-based design studio develops innovative product solutions that strengthen brands and improve the user experience.
Powder coatings have long been indispensable for the sheet metal processing industry and the automotive sector, with which Kaliauer works together closely. The technology offers advantages that wet paint often cannot match – especially in terms of durability and surface quality. The product designer plans to use powder coating primarily for industrial metal parts where mechanical resistance is key. Including machine housings, motorcycle frames or heavy components such as excavator components. Thanks to its properties, powder can also be used to coat complex structures and angled geometries reliably and evenly.
According to Kaliauer, colour accuracy and compatibility with different materials are also crucial, as different plastic components, anodised aluminium elements and powder-coated frames often have to blend together seamlessly on the end product.
Bernhard Kaliauer has known the TIGER brand since he was a trainee. Today, he works with the free TIGER Digital Finishes on a daily basis. “TDFs are irreplaceable in my work process,” says Kaliauer. “The digital finishes help me to present products in a photorealistic way and make agreements with customers more efficient and realistic.”
Even with a colour such as grey, which can have numerous nuances,
accurate colour reproduction poses a challenge. With TDFs, Kaliauer ensures that his renderings are almost identical to the end product in terms of colour tone and texture – a quality that he is unfamiliar with from other manufacturers in this form. “I used to have to painstakingly and time-consumingly recreate material surfaces in my design software. Today, the digital surfaces from TIGER allow me to display them easily and realistically on calibrated monitors.”
Kaliauer wholeheartedly recommends the TDFs to anyone who has high demands when working with colour. “TIGER Digital Finishes are priceless in my work,” he summarizes. “They enable me to present my customers with photorealistic results that can also be implemented precisely in the subsequent production process.”
All powder coating products from the TIGER Drylac® standard range of over 1,500 finishes are scanned at TIGER's headquarters in Wels, Austria, and made available free of charge as digital files in the webshop. On request, TIGER also scans individual colour nuances of its customers. In the first step, a sample panel in the desired colour is coated with TIGER Drylac® powder coating; The panel must be completely flawless after coating application. Even the smallest scratches can have a negative effect on the subsequent scan result;
The coated effect pattern is placed in a special material scanner and digitally reproduced as an AxF file; To create a so-called “seamless material”, the AxF is then processed. This allows the texture to be applied to a model without repeating or “tiling”; For customers whose rendering program does not support AxF files, the scanned surfaces are exported separately as texture maps in the EXR format; Using the AxF material, TIGER creates its own visualizations within Keyshot, such as the spheres, photos or videos for the web store as .jpg and .mp4; All files are then stored on the TIGER server and made available via the webshop.
The coated sample panel is placed in a special material scanner and digitally reproduced as an AxF file, allowing the texture to be applied to a model without repeating or “tiling”.
Federico Melideo ipcm®
Powder coating contractor Metalux has recently adopted the new nanotechnology product Dollcoat RS 103 from DN Chemicals for the pre-treatment phase performed in one of its numerous coating lines. The aim was to achieve high corrosion protection performance with a single paint layer, thus effectively tackling current market challenges.
The industrial coating sector is increasingly competitive and calls for innovative solutions to ensure product quality and durability. In this context, Metalux1 (Castelfidardo, Ancona, Italy), a company specialising in contract powder coating services, has risen to the challenge by choosing to employ in one of its coating lines the new nanotechnology pre-treatment product Dollcoat RS 103 from DN Chemicals. This Milan-based formulator and distributor of chemical specialities for surface treatments has selected Metalux as its partner for a pilot project aimed at testing the potential of its innovative technology, developed to achieve high corrosion protection performance in one coat.
1 https://www.ipcm.it/en/open/ipcm/2019/56/130-134.aspx
Giacomo Bettucci, at the helm of Metalux, emphasises the importance of the cooperation with DN Chemicals: “It has been a partner of ours for over ten years and often supports us as a consultant in the assessment of specifications. Given the importance of chemical pre-treatment in coating processes, especially in corrosion protection applications for outdoor components requiring highperformance treatments, when they asked us to test their new nanotechnology product using one of our coating lines as a pilot plant, we enthusiastically welcomed this opportunity. To do this, we revamped the line’s cleaning tunnel and application system, as the new nanotechnology agent has a different chemical formulation than the previously used one.”
André Bernasconi, the General Manager of DN Chemicals, adds: “We chose Metalux as a partner for the Dollcoat RS 103 industrialisation pilot project based on our solid, ten-year partnership and because of its positive approach to technological innovations, making it open to collaborate on this with professionalism and critical sense.”
characteristics of Dollcoat RS 103
“This new product range is a significant advancement over previous ones, based on synthetic silane compounds already complex by nature. This innovative technology is based on polymers functionalised with highquality anti-corrosion additives, developed in collaboration with international partners with whom we share patent rights,” explains Bernasconi.
“Dollcoat RS 103 is a nanotechnology passivating agent designed to meet the needs of companies wishing to achieve a corrosion resistance class between C3H and C5H with a single coat of paint. This product is very versatile, as it can be applied on all types of metal, including iron, galvanised steel, and aluminium. That makes it suitable for a wide range of industrial and commercial applications, where it can consistently guarantee high performance.”
“We performed several preliminary quality tests, including electrochemical impedance spectroscopy, which is useful for comparing application cycles and optimising results, and ACET, used for the preliminary assessment of corrosion resistance, to ensure high quality standards could be achieved in each application cycle. Another analytical system we utilised was Raman spectroscopy, a technology that, despite being on the market for years, we were the first to use in the context of surface treatments to provide detailed coating quality assessment and preventively address potential issues.”
The atomising module for product application
“Dollcoat RS 103 is applied using our proven atomisation technology, designed to ensure precise application of small quantities of fresh product. This system ensures uniform application, reduces waste, and makes the process more sustainable. Although the purchase cost of Dollcoat RS 103 may be higher, the atomisation technology is optimised to minimise material consumption, reduce aesthetic defects due to dragging among baths, and eliminate the need for product recirculation, an option made possible by the product’s formulation, which is highly resistant to pollutants. Our newest atomising module enables contract coaters to keep process costs within pre-set limits and to maintain excellent control over all operational parameters, as required by most specifications and quality procedures,” states Bernasconi.
Advantages of the new nanotechnology passivating agent
“Adopting Dollcoat RS 103 has been a remarkable qualitative step forward for Metalux, enabling us to operate in new international markets with demanding specifications, such as the automotive sector or QUALISTEELCOAT, for which METALUX is already certified up to class C4H using products from the Dollcoat series. After conducting some preliminary tests on a series of samples normally requiring two paint coats, i.e. primer + topcoat, the results of a conversion cycle with Dollcoat RS 103 + one coat of polyester powder were promising: the new product ensures significant savings compared to the two-coat process without compromising the protective performance of the finish,” notes Bettucci.
“The salt spray tests conducted on cold-rolled steel pre-treated with Dollcoat RS 103 and a layer of Qualicoat 2 certified polyester coating gave a result of 1200 hours of resistance, with a maximum penetration of 1 mm at the notch. With aluminium, the result was 2000 hours of resistance in acetic salt spray, again using samples finished with one coat of Qualicoat 2 certified polyester paint,” adds Mara Pege, laboratory manager at DN Chemicals.
“I am confident in the potential of this new product. Combined with our plant, capable of handling large-sized components, it will enable us to access new markets and expand our capabilities,” concludes Metalux Srl’s owner, Giacomo Bettucci.
“The development of these products is only in its infancy. Metalux will start with Dollcoat RS 103, the result of more than two years of experimentation, already on the market and protected by an international patent. Currently, this range only consists of multi-metal agents, but we are developing specific solutions for materials such as aluminium and galvanised steel. The first two products we will supply to Metalux, Dollcoat RS 103 and Dollcoat GP 107, will be applicable by dipping, spraying, and atomising. Finally, its plant will be the first to integrate a product recovery system to recycle and reuse the amount of atomised material that does not remain on the treated components’ surfaces,” summarises André Bernasconi.
A large global manufacturer of high-strength stainless steel mesh for security screens and doors was facing high costs and process efficiency-related challenges, leaving a plant unused. By implementing the FASTRIP FP system with the Metalstrip 1334, Aktivator 1533 and AlitFlock products from ALIT Technologies Spa, it became however able to start performing an effective in-house paint stripping process, reducing operating costs and improving quality.
For many companies, operating a chemical paint stripping plant means facing high costs and process efficiency-related challenges. That was the case with a large customer in the industrial coating industry, which was leaving a plant unused due to the ineffectiveness of the previously adopted chemical products. The plant was too expensive and complex, and it was never successfully started. The company, which prefers to remain anonymous, is a large global manufacturer of high-strength stainless steel mesh for security screens and doors, specialising in the design and production of security mesh systems that offer protection from intruders, insects and environmental factors without compromising visibility or airflow. Its products are widely used in residential, commercial and industrial applications, ensuring safety, durability and aesthetics. Focusing on innovative technology and precision engineering, it provides certified, high-quality solutions also
exported to several international markets. Its commitment to safety, quality and performance sets it apart and positions it as a key player in its industry.Faced with the difficulties mentioned above, the customer turned to G&R Finishing Equipment – a long-standing distributor of ALIT Technologies products with twenty-seven years of experience in providing powder coating solutions, recognised for the high quality of its equipment and services. G&R thus turned to ALIT Technologies Spa to find a definitive solution and transform an idle plant into a productive and efficient resource.
G&R Finishing Equipment: a major supplier of powder coating solutions
Based in Thailand and family-operated, G&R Finishing Equipment Co. Ltd. imports, assembles and distributes powder coating machinery,
providing high-quality equipment and excellent after-sales services for customers in various industries. It offers customised solutions ranging from small equipment to advanced industrial systems, working with international suppliers to ensure the best performance and durability. In addition to the supply of machinery, it offers after-sales services such as training, maintenance and ongoing technical support, which ensure optimal operation of customer equipment over time. Its collaboration with ALIT Technologies arose from the need to address some coating efficiency and uniformity issues, when Somboon Jongdepaisarn, the Managing Director of G&R, saw the Italian business as the ideal partner to tackle these challenges. Through this partnership, G&R has been able to offer its customers innovative and sustainable solutions aligned with their mission to improve product quality and reduce waste in the Thai market.
An innovative and collaborative approach
Before ALIT technologies’ intervention, the customer had been experiencing great frustration. The quality and precision of its powdercoated products had always been a priority, but high costs per unit and treatment quality problems were significant obstacles. Some coated parts did not pass quality controls due to surface defects, leading to a scrap rate that generated additional costs. The company had long searched for a compatible paint stripper for its perforated aluminium and mesh products, but it had been unable to find an effective one. The paint strippers it had tried were difficult to use and had a high risk of causing further defects during paint removal.
G&R Finishing Equipment suggested ALIT technologies’ products as a solution to these coating issues. As mentioned, the customer had previously used some paint strippers from other brands but found them ineffective, as they failed to thoroughly remove the paint from its coated parts, leading to inefficiencies in its manufacturing process.
G&R proposed conducting a trial, and the customer agreed to send its products to test ALIT’s paint stripping technology, asking to recommend the solution best suited to its specific needs. The project started with a thorough analysis of the plant and its critical issues. ALIT Technologies adopted an innovative and collaborative approach, suggesting the installation of the FASTRIP FP 400-17P advanced filtration system to treat the sludge formed by the paint stripping process. That allowed the paint stripping bath to be regenerated by filtering the sludge and the chemical to be reused, thus minimising waste and extending the life of the bath itself.
For the plant’s operation, the company also provided its Metalstrip 1334 and Aktivator 1533 chemicals, which can paint strip various materials precisely and effectively. Using Metalstrip 1334 at 50 °C, materials such as stainless-steel mesh and perforated aluminium profiles could be
treated in about 60 minutes. Aktivator 1533 ensured stable alkalinity in the bath, improving the efficiency and consistency of the process.
The technology adopted and the results obtained
The core of the project was the installation of the FASTRIP FP machine, which, thanks to pressure filtration, made it possible to keep the chemical bath operational for longer periods, thus reducing the frequency of maintenance work.
In addition, using the AlitFlock flocculant further optimised the quality of filtration, reducing cycle times and improving process sustainability. The trial’s results were extremely satisfactory. The customer was able to paint strip all coated parts with 100% efficiency, which enabled it to
recover defective parts instead of discarding them, significantly reducing waste and costs. In addition, the Metalstrip 1334 paint stripper worked much faster than previous products, saving valuable time during the removal process. At the same time, the customer had a massive number of workpieces to be stripped per day, and the only economically sustainable solution was to filter the bath. In fact, ALIT technologies demonstrated that the flocculant and Aktivator consumption rate was significantly lower with a filtering system than through bath replacement. Specifically, every 300 kg of paint removed corresponded to a consumption of 1,000 kg of Aktivator. Another supplier (which did not provide filtering units) had suggested changing the stripping bath every month, which would have meant handling 8,000 kg of material to be disposed of and replaced – an unaffordable solution for the customer. In essence, the ratio was 1 to 8, making the investment in the filter press cost-effective and quickly amortisable.
The collaboration between ALIT Technologies Spa and G&R Finishing Equipment
Pietro Mandorino, area manager at ALIT Technologies Spa, followed this project closely, working jointly with the company and its distributor, G&R
Finishing Equipment. He provided comprehensive support, not only from a technical point of view but also by managing logistics, facilitated communication among all parties involved and ensured continuous attention to the needs of the customer, dedicating himself to overseeing every phase of the project and making sure that every detail was handled with precision and timeliness: “It was a complex challenge but also a huge opportunity for growth. Thanks to the synergy among ALIT, G&R and the customer, we were able to regenerate a plant that is now finally operational and productive, exceeding initial expectations.”
“I would also like to stress the importance of the contribution provided by ALIT Technologies: its products and solutions have led to a great step forward, offering an unprecedented degree of quality and efficiency. Although preferring to remain anonymous, the end-customer confirmed its satisfaction: it finally sees its plant working to its full potential. Costs have been reduced, and it is able to achieve a paint stripping quality that it did not think was possible,” has added Somboon Jongdepaisarn, the managing director of G&R Finishing Equipment.
Dedication leads to innovation. Quality creates value
From an interview with Matteo Caroli
CEO of Teknox Srl
The new 3DWAVE machine specially designed for dyeing 3D-printed parts is the result of the synergy between two Bologna-based companies, Teknox and Norblast, specialising in the chemical and mechanical treatment for parts of any shape and material, respectively, which have combined their skills to create a new technology that fills a gap in a strategic market segment. In this article, Matteo Caroli, CEO of Teknox, illustrate the development and the characteristics of this new system that... breaks the mould with the past of AM post-processing.
Additive Manufacturing (AM) is a production technology that builds three-dimensional objects by superimposing layers of plastic, metal, or, more recently, even ceramic and glass. The process is based on computer models created using specific design software. Its final stage, where the actual production takes place, is commonly known as 3D printing.
Originally used for creating prototypes prior to large-scale production or one-off products made in small batches, it has now become essential in sectors such as biomedical, aerospace, nautical, automotive, and even fashion and fashion accessories, where customisation and production flexibility are crucial and where the market imposes ever-more perfect aesthetic requirements for moulded parts. It is precisely in the postprocessing phase of these components that finishing – particularly dyeing – technologies are making significant advances.
Traditionally, especially for high-end products, industrial machines equipped with cartridges for colouring with different dyes are used in the AM post-processing phase. However, the investment for these systems is considerable, and the cost for users is very high. In addition, the dyeing technique is artisanal, more similar to textile dyeing techniques then to an industrial process. These systems present a greater risk to health and the environment and, at the same time, did not ensure optimal and, above all, repeatable results.
Norblast’s technical team of experts in mechanical cleaning systems for various materials and 3D-printed parts thus sought a reliable partner with in-depth knowledge related to liquid management to develop a machine able to fill the existing technological gap. It turned to Teknox Srl, a long-standing company that designs and manufactures plants for the industrial cleaning of metal components. The combination
of Norblast’s profound knowledge of the pre-dyeing phase of AM processes and Teknox’s liquid management know-how has resulted in 3DWAVE (patent pending in 2023), the first all-in-one system for dyeing 3D-printed parts.
When mechanical engineering and chemistry meet
The prototype of the new machine was developed from a concept created by Teknox for a cleaning system. “We had the opportunity to test the prototype at a company used to high production throughput,” explains Teknox’s CEO, Matteo Caroli. “That has enabled us to speed up the testing phase. The machine worked well, proving the ideal solution for achieving outstanding, repeatable results and maximising productivity. This innovative immersion dyeing system guarantees colouring precision and consistency, becoming an ally for companies that 3D-print small and medium-sized components and need an efficient and reliable machine.”
French company TCN - Techniques Chimiques Nouvelles supplies the dyeing products. TCN is a solid reference in the AM market for the production and distribution of dye liquids. Norblast’s expertise in pre-dyeing and Teknox’s experience in liquid management were thus complemented by TCN’s know-how in developing the most suitable formulations for reliable and marketable products meeting all customer requirements, from UV resistance to suitability for bonding.
A machine structure borrowed from cleaning technology
The structure of 3DWAVE is based on that of an industrial cleaning machine. It has a 160-litre immersion vat located in the lower part of the system, as in a cleaning plant, where the TCN dye is mixed with water and where the dyeing operation takes place, a 450 x 300 x H 300 mm workpiece holding basket with a maximum capacity of 50 kg, and a spray
pipe in the upper part for pre- and post-dyeing rinses. Components printed with MJF-SLS technology have a layer of semifused powder that needs to be removed. With Norblast technology, it is possible to completely clean the residues and perfectly prepare the parts for the next dyeing phase.
Once the basket with the workpieces placed in bulk is inserted into the machine and the lid is closed, the dyeing process starts. It consists of 4 stages: preliminary rinse to remove any surface impurities, dyeing using the RotoWave technology, with slow rotation on a horizontal axis and partial immersion, final automatic rinse to remove any excess dye, and, finally, hot air drying in a micro-filtered, temperature-controlled environment. The RotoWave technology, thanks to its partial immersion and continuous product change features, allows the liquid to move constantly and even enter deep cavities, improving the dye’s ability to adhere to surfaces and avoiding stagnation and/or halos. The entire cycle lasts less than an hour, depending on the phases activated in the programme, the longest one being dyeing (about 20-30 minutes). Afterwards, the parts can be immediately manipulated and have a perfect aesthetic appearance.
Features of 3DWAVE
The machine is W 1300 x D 960 x H 1200 mm in size and weighs 260 kg. It can dye up to an entire HP Jet Fusion 5200 build unit with 10% dye liquid in water, i.e. about two 10-litre cans of TCN product. It operates at an adjustable temperature of up to 80°C.
Table 1 summarises the main technical features of the system.
Advantages of the new dyeing machine
“This solution changes the approach to immersion dyeing 3D components, evolving from a craft method to an industrial process,” emphasises Caroli. “In addition to the already mentioned advantages,
including repeatable results and high production capacity, 3DWAVE brings further benefits: an all-in-one process that incorporates all the required surface treatment steps (pre-rinsing, dyeing, rinsing, and drying), optimal results even on complex surfaces thanks to Teknox’s RotoWave technology, reduced running costs through lower energy consumption, less product consumption and disposal costs, and high productivity thanks to the one-hour cycle time. The system is also easy to use, with simple programmes tailored to each customer’s needs, and Industry 5.0-ready, thanks to software that analyses and stores daily electricity consumption data, enabling optimised consumption control and management. Last but not least, the finished part obtained is an industrial product, the result of a clean, safe, and environmentally friendly process. The operator’s intervention is limited to loading and unloading the basket and refilling the dyeing product if necessary.”
Future developments in the new dyeing technology “Compared to coating or other dyeing methods,” says Caroli, “this process has a reduced cost, can reach every surface area of the treated workpiece, and is more effective because it does not entail the application of a paint film but rather the absorption of a dye and water. It also has countless applications and allows for truly rapid cycles. From an aesthetic point of view, the results achieved are as requested by the customers.”
“The challenge that Norblast threw at us two years ago was not an easy one to take on,” Caroli concludes. “However, we at Teknox are always ready to experiment with new projects, and this one, which filled a gap in a market segment that immediately seemed strategic to us, intrigued our team, who soon started working with Norblast’s one to achieve results. Today, building on our cleaning expertise, we have created a machine that offers an innovative opportunity for Additive Manufacturing professionals.
The turtle model was created by Ferocar, reproduced here without modifications and distributed under a Creative Commons licence. Attribution: https://creativecommons.org/licenses/by/4.0/deed.it, downloadable from https://www.thingiverse.com/thing:3753213
Size of the workpiece holder 450 x 300 x H 300 mm – mesh 12 x 12 mm
Production volume per cycle Up to an HP Jet Fusion 5200 full build unit
Cycle time 30-60 minutes (depending on the activated program phases)
Pre-rinse and post-rinse Integrated into the treatment cycle
Heated air drying Integrated into the treatment cycle
Liquid working temperature 60 °C – 80 °C
Liquid dye percentage 10% in water
Tank capacity 160 l
Machine external dimensions W 1300 x D 960 x H 1200 mm
Weight ~ 260 kg
Electricity supply 3 PH 400 V 50 HZ + N + PE, total power 7 kW
Water supply Pressurised mains water; softened water recommended
Compressed air Pressure: 6 bar – Flow: 20 Nmc/h
Josh DeLozier
The University of Oklahoma - Norman (OK), United States joshdelozier@ou.edu
The University of Oklahoma has received a $4.8 million commitment from the Oklahoma City Air Logistics Complex at Tinker Air Force Base to create a primer free of chromium containing materials to protect U.S. military aerospace equipment from corrosion.
Led by the Gallogly College of Engineering and Oklahoma Aerospace and Defense Innovation Institute at University of Oklahoma, this project will evaluate chrome-free commercial and experimental primers that eliminate exposure of materials of concern to
workers as well as providing more environmental-friendly solutions.
“Our ability to collaborate with the University of Oklahoma researchers is vital to the Air Force’s ability to meet future mission challenges,” said OC-ALC commander, Brig. Gen. Brian R. Moore.
“This project is one of many that we are working with OU to improve our sustainment and modernization capabilities to further protect our workforce.” “This project greatly expands our ongoing research efforts to develop novel, chromium-free organic coatings. These primers will provide excellent corrosion protection and adhesion to pretreated aluminium alloys while offering exceptional fluid resistance and outstanding flexibility,” said John Klier, project principal investigator and dean of the Gallogly College of Engineering.
Beginning in 2021, University researchers began working with the OC-ALC to evaluate and identify epoxy-based primer compositions. Their goal was to help the U.S. Air Force eliminate the use of hexavalent chromium and reduce environmental
impact and the associated costs with its use and disposal.
According to Klier, the research team has developed several chrome-free prototype additive systems, and spray and testing infrastructure are in place. Application and evaluation of the formulation are underway.
“Our bond with OU is instrumental to our ability to meet future mission challenges,” said Gen (ret) Robin Rand, OADII executive director. “These awards strengthen our educational partnership agreement with the OC-ALC and are an outstanding example of how the university’s growing research and development in the national security sector can impact some of the most pressing needs of the Air Force today and for years to come.”
Klier will lead the project alongside Brian Grady, the Douglas and Hilda Bourne Chair of Chemical Engineering in the School of Chemical, Biological and Materials Engineering, and Wilson Merchán-Merchán, an assistant professor in the School of Aerospace and Mechanical Engineering. The project will be managed by OADII Director of Operations LTC (ret) Cliff Wojtalewicz. OU signed an educational partnership agreement1 with the OC-ALC in July 2020 to cultivate aerospace and defence technology development and to improve and enhance education in science, technology, engineering and mathematics.
Founded in 1890, the University of Oklahoma is a public research university located in Norman, Oklahoma. As the state’s flagship university, OU serves the educational, cultural, economic and health care needs of the state, region and nation.
Leading companies rely on vacuum distillation systems for the sustainable treatment of industrial wastewater.
Do you want to benefit from a zero liquid discharge production with VACUDEST aswell?
1 https://ou.edu/research-norman/news-events/2020/oc-alc-teams-up-with-ou-on-educational-partnership-agreement
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The partnership between artist Mariko Mori and Lechler is renewed once again in the beautiful setting of Venice.
Japanese artist Mariko Mori has once again chosen Lechler products for her latest monumental work presented in Venice last June. It is called Peace Crystal, and it is a site-specific installation that invites reflection on our common humanity. The outer shell, which contains a 165-centimeter tall artwork made of quartz glass, majestically rises in the garden of Palazzo Corner della Ca’ Granda.
Peace Crystal represents the human body as a container of the eternal soul, which traverses life, death, and rebirth. The elongated shape of the work, reminiscent of a crystal, evokes human evolution, specifically the moment when humans stood upright. This crucial event, according to the artist, led to the development of intelligence and spirituality.
The illumination of Peace Crystal is a fundamental element of the work. An external solar collector gathers light and passes it through quartz glass optical fibres, transmitting real light within the artwork. This light gives Peace Crystal an aura of life and vitality, symbolizing the energy that animates the universe and our very existence.
Peace Crystal is a work that invites reflection on our common humanity, our connection to the universe, and our responsibility toward the planet. Mariko Mori’s work is a message of peace, unity, and hope for a better future. The installation was open to the public free of charge until October 7, 2024.
After the exhibition in Venice, Peace Crystal was donated to Ethiopia and permanently installed in a cave, thus honouring the origins of humanity, which begin in Ethiopia, the cradle of evolution for over six million years.
The artwork reminds us that we all belong to a single family tree and that all individuals in the world are part of a shared humanity.
Andrea Siano Argos ST Group
The Argos ST Group, a leading company in the field of coatings and surface treatments, has invested in the implementation of solutions capable of improving the performance and durability of vehicle components such as grilles near the muffler, brackets, and even motorcycle crankcase covers.
The Argos ST Group is an important company of coatings and surface treatments, especially when it comes to application for the automotive industry. Its plants are specialized in solutions that can improve the performance and durability of the components of the vehicle such as grilles near the muffler, the brackets, but also the crankcase covers for motorcycles. All elements that require resistance to high temperatures, UV radiation and any type of solvent or greasefor parts subject to environmental stress - as well as an anti-corrosive
capacity for the longevity of the pieces and a quality aesthetic yield. Every element that defines the vehicle must be durable also for aesthetic purposes and for safety. Characteristics that define the production of Made in Italy that are appreciated especially abroad. In fact, even if according to the preliminary data of ANFIA, the production of cars in Italy fell by 3.2% on January-March 2023, instead the industry’s turnover grows in the strict sense - excluding the construction sectorthat in February 2024, (last available data) recorded a positive variation
of +1.3%, with a +3.2% on foreign markets. The export of automotive components is worth 2.1 billion euros, demonstrating how Italy continues to recover the sector thanks to the quality of the solutions of local companies1
“We need to promote Italian excellence and the know-how of small and medium-sized enterprises to increase business through quality and innovation. In Italy we have all the capabilities to do it” says Andrea Siano, President of the Argos ST Group “At Argos we have been operating in this sector for years and we are able to offer coatings and treatments that improve the performance and durability of automotive components, with solutions tailored to the specific needs of each customer. We want to be part of an ecosystem that can grow both in terms of internal production and in terms of exports. That’s why we continue to research new solutions and implement innovative systems to support Made in Italy”.
The Argos Group is specialized in coatings and surface treatments and recently the plants of Minerbio, Origgio and Opera - with their many years of experience - have produced covers characterized by resistance, anti-friction and anti-corrosion. Specifically, the Minerbio’s plant succeeded through the Teflon-coating technique to respond effectively to the demand for grilles near the muffler that were resistant to temperatures up to 260 p. centigrade and that respected the company’s aesthetic standards for a company of super sports cars of Bologna, that commissioned the production. At Origgio the process with Sol Gel, water-based ceramic coating, developed by professionals in the province of Varese has allowed to treat the brackets of some luxury cars giving it a high resistance to UV radiation and any type of solvent, offering particular hardness, resistance to abrasion, high temperatures and extreme environmental conditions.
1 Source: https://www.anfia.it/it/comunicazione/comunicazione/notizie-e-comunicati/comunicati-stampai/produzione-industria-automotive-italia/in-calo-a-doppia-cifra-lindice-della-produzione-dellindustry-automotive-italian-March-17-7-5
Not only four-wheeled, in fact in Opera, the Argos ST Group’s technical and hard anodising specialists - used when there is a need to offer particularly high wear resistance, anti-corrosion and sliding characteristics - collaborated on a cover on crankcase covers intended for a competition motorbike model.
“The world of cars - like that of two-wheeled - is constantly subjected to rapid innovation processes, which make it one of the markets where production efficiency defines the success of a company”confirms Dr. Andrea Siano “The treatments offered by the Business Units of the Argos ST Group play an important role in the competitiveness of the sector’s production system, as they guarantee high and lasting performance. Thanks to the know-how of individual plants and the ability to offer customized solutions, the Group continues to be a reliable partner for the automotive industry and for its relaunch globally”.
Set up by the private equity fund Gradiente II, managed by Gradiente SGR, in 2020 the new Argos Surface Technologies Group is born from the merger of important companies in the metal surface treatments and coatings sector, with the aim of creating a leadership in the sector. In 2020 the Group starts with the acquisitions of Argos, Impreglon Italia and Aalberts ST in Opera. In 2021 it acquires Emilia-based TSM Srl, today Argos TSM, and Lualma Anodica, today Argos Lualma; in 2022 it is the turn of Bergamo-based Tec.Ri.Met.. Finally, in 2023, the merger of Mantova-based Foresi and Turin-based Rotostatic into the Argos ST Group was formalised, and Galvanotecnica Salvatori Bologna, today Argos GSB, was acquired. The Group now boasts ten plants: Borgaro Torinese (TO), Origgio (VA), Opera (MI), Cambiago (MI), Calcio (BG), Gonzaga (MN), Monteveglio (BO), Minerbio (BO), Castenaso (BO) and Imola (BO) with over 350 employees and a turnover of around 60 million euros.
In a location of the past, eos mktg&Communication celebrated its present with an eye to the future, offering its guests a digital experience that projected them into what lies ahead in digital communication by unveiling the potential of tools such as 3D animation, logo animation, artificial intelligence, and much more to promote brands and products.
B2B or B2C, communication travels fast and evolves continuously: the solution to keep up with the times and reach one’s target audience is a mix of traditional and digital communication aimed to be present in all existing channels coherently and effectively.
That is what eos intended to communicate on the occasion of its anniversary. eos assists companies in developing their marketing
and communication strategy while also supporting them in organising events, trade fairs, conventions, and corporate conferences. Added to this is the technical dissemination work carried out with its international ipcm® magazines, targeted at the surface treatment industry and distributed worldwide.
To celebrate its first 15 years in business, eos organised a party on 24 July, inviting all of its customers to retrace its origins and its journey to date, but also provide insights into the communication of the future. We wanted to offer an evening of pure fun!
Organised at DASTE, a former thermoelectric power plant on the outskirts of Bergamo (Italy) that is now an open hub for socialisation and exchange, promoting new technologies and contemporary languages, #EOS15 was an event with no institutional moments but rich in engaging experiences. The Diamonds band entertained our guests for the entire duration of the party with an energetic and captivating show, playing the best international and Italian hits of the last 20 years; an omnidirectional digital photo platform made it possible to capture the highlights of the evening and create beautiful memories for everyone; and the projection of a 3D animated video showed how to bring a company into the digital era.
Changing the form while maintaining the essence.
Edited by Assovernici Milan (Italy) info@assovernici.it
Assovernici, the Italian association representing the major producers of industrial and building coatings, presented its new Sustainability Report at the latest Product Sustainability Summit Europe held on November 25 and 26 in Cologne (Germany). Building on companies’ increasing awareness of environmental and social issues thanks to the now well-established ESG criteria, this Report aims to quantify members’ commitment and thus outline a valuable benchmark for charting the path to a truly sustainable transformation. In this interview, Paolo Bonamigo, the Head of the Technical Regulatory Area of Assovernici, describes the current state of the industry as portrayed by the Sustainability Report and discusses the new challenges to be overcome and the new goals to be achieved, starting with the formulation of products complying with the current (although not fully defined yet) regulatory framework.
During the latest Product Sustainability Summit Europe, the focus was on how manufacturers and their suppliers can navigate an increasingly complex sustainability-related regulatory landscape. What are the main areas in which member companies are directing their efforts?
There are two main areas. The first one is responsible resource management with a focus on water consumption. The overall goal is to reduce waste and optimise the use of raw materials to increase production volumes while consuming less. At the same time, great attention is also paid to energy efficiency through an increasing use of energy from renewable sources, both with in-house plants and through external suppliers.
This year, Assovernici published an ambitious Sustainability Report, which was presented at the event. By what criteria was the document produced and with what objectives?
Assovernici’s Sustainability Report was produced with the aim of gaining a concrete understanding of how the industry we represent is
performing. Its starting point was a project initiated by our Sustainability Committee that first enabled us to develop a set of key indicators to monitor the main environmental aspects of our member companies over the past five years. This was complemented by an extensive survey administered to our members last year to track social and governance factors. The responses enabled defining a benchmark for companies in the sector, stimulating them to improve their performance with an approach beyond mere self-referential communication. The resulting document constitutes an important reference point for companies wishing to commit to a path of sustainability, all the more so because the data collection process is particularly accurate as it was carried out by an independent organisation external to the Association, which made it possible to outline a faithful and detailed overview of the sector.
What are the key indicators and most interesting experiences that have emerged?
Certainly noteworthy is the growing attention of members to issues related to sustainable management in the broadest sense of the word, including social and governance aspects. On the production side, we have found that some environment and safety-related certifications are adopted almost uniformly, even by small companies, for which obtaining them entails a considerable financial commitment, as well as constant monitoring, which is essential to maintaining high standards.
What tools and certifications are most widely adopted by members?
The Sustainability Report shows that Assovernici’s member companies are increasingly attentive to indicators related to emissions, and generally focussed on certifications related to the environmental aspects of organisations or products. Let us not forget that legislative drivers requiring more and more specific tools are on the rise: under the spotlight, for example, are no longer only the so-called Scope 1 and 2 emissions (i.e. direct greenhouse gas emissions and indirect emissions resulting from the generation of purchased and consumed electricity, heat, and steam, Ed.) but also those identified as Scope 3 (i.e. produced by suppliers and customers).
What are those destined to attract increasing attention in the near future?
First of all, it is essential to remember that the paint and coatings sector is among the main ones affected by the EU Regulation 2024/1781, called Ecodesign for Sustainable Products Regulation (ESPR). As we know, this is a tool to define the design characteristics for products to be considered environmentally sustainable, from the responsible use of
resources to the recyclability of components and the traceability of any critical substances.
Therefore, it is going to be increasingly important to have adequate tools to provide the necessary traceability information and meet the obligations imposed by Directive 2022/2464, called Corporate Sustainability Reporting Directive (CSRD). Aware of the importance of these aspects, our Association focused its last general assembly on CSRD-related issues as an opportunity to develop one’s ESG identity. However, how the new Commission will implement these regulations will be decisive: hopefully, it will aim to prevent excessive bureaucratic pressure from undermining the competitiveness of companies.
Are any particular new features expected for the next edition of the Report?
For now, our Association intends to continue with an annual data collection process to trace increasingly significant trends while ensuring continuity: in my opinion, it is in the third edition that some novelties could be expected.
How can it stimulate member companies to evolve on their path toward sustainability?
As mentioned, drafting a Sustainability Report can lead member companies to evolve on their path toward sustainability in several ways. In particular, including a comparative analysis or benchmarking process can allow them to compare their performance with other companies in the sector, stimulating them to improve their internal practices. In short, benchmarking can contribute to setting more ambitious sustainability targets.
What are the most demanding regulatory challenges today?
The current regulatory landscape poses significant challenges to chemical companies, mainly due to the ESPR Regulation, which I have already mentioned, and the pending reform of the REACH Regulation. With regard to the latter, the main difficulties for companies arise from uncertainty in implementation since several aspects are yet to be defined, such as the registration of polymers and the possible restrictions on the use of substances in consumer products, which could significantly affect our member companies.
To further complicate the situation, CSRD and ESPR add to an already complex regulatory environment, which places significant demands on businesses to maintain compliance. Finally, the current economic and political scenario, characterised by extreme uncertainty, inflation, and supply bottlenecks, makes it even more difficult for companies to sustain the commitment and investment needed to ensure compliance.
Joerg Zumkley
BASF Coatings GmbH – Muenster, Germany joerg.zumkley@basf.com
The theme of BASF’s new Automotive Color Trends – ROUTING – is inspired by communication technologies and redefines colour palettes with new nuances of reds, blacks, metallics, and more.
Every year, designers from BASF’s Coatings division create a new collection of colours to inspire automotive designers around the globe. “ROUTING”, the title of the 2024-2025 Automotive Color Trends, refers to the concept of “routing” in communication technology which signifies how information is transmitted.
“In our trend observations, we have identified the way we communicate and handle information with human or non-human intelligence as a strong driver for trend developments,” said Mark Gutjahr, global head of Automotive Colour Design at BASF. “Communication is lively, everchanging, and mutually receptive – just like colours.”
Reflecting the evolving nature of communication
ROUTING reflects the evolving nature of communication through a diverse palette of colours, backed up by key statements from BASF’s design experts. This year’s trends feature new reds with intense purple shades, signifying a shift from darker and blueish reds. The dark achromatic colours have been energized by intense colour effects, offering dynamism beyond solid black. Fine metallic effects are particularly characterized by strong effects on the surface, which give metallics new radiance.
The spectrum of pastel colours continues to diversify, for example in beige and light green tones already available in the market, as well as in unusual intermediate tones. Sustainability and functionality remain core themes in ROUTING, with colours developed using renewable, recycled, and bio-based materials, and optimized for sensor-based driving systems.
As automotive OEM customers rely on the BASF colour trends for designing automotive colours for their future models, end customers may witness the new direction on the road or in their driveways within the next three to five model years.
HARBINGER’S INK in EMEA – a deep black hue enlightened by sustainability
In EMEA, HARBINGER’S INK emerges as a powerful key colour based on the awareness that natural resources are finite. With a unique and unseen sparkle effect, this strong black colour is enhanced by the combination of carbon-negative and renewable components, as well as biodegradable pigments.
“HARBINGER’S INK represents the crucial integration of environmental responsibility into automotive design,” explains Gutjahr. “It signs the deal for a direct connection from a strong colour position to a sustainable concept.”
SCINTILLATION in Asia Pacific – Metallic and sustainable concepts on a new path
SCINTILLATION stands out in Asia Pacific with its smart warm grey and liquid metal effect designed by a novel, low-emission basecoat technology. This colour implies the future affinity between human and non-human intelligence, and enhances the brand value of high-end vehicles and their quality and sustainability.
“SCINTILLATION captures the region’s drive for refined yet forwardlooking design,” notes Chiharu Matsuhara, head of Automotive Colour Design for Asia Pacific. “It aligns with the region’s focus on creating high-quality, sustainable automotive solutions that resonate with both technological advancement and enduring values.”
HOLDING SWAY in Americas – where dual hues appear to synthesize as one
In the Americas, HOLDING SWAY is a prominent colour that signifies the merging of dual hues and cooperative energies. This colour features an intense purple shade with strong blueish shift effect.
“In various facets of society, diverse influences come together and inspire innovative solutions for products. By creating connections and bridging opposites, new opportunities and spaces emerge for the way people consume, communicate, and experience mobility,” elaborates Lizzie-Marie, Lead Colour Designer for the Americas. “In HOLDING SWAY, the value of transparent and cooperative energies merging to form innovative paths are symbolized.”
Every year, the designers of BASF’s Coatings division study future trends which they use as foundation for the development of surface, texture and colour positions from a wide range of areas, including industry, fashion, consumer products, nature, and technology. The research is then shared with BASF’s automotive customers to drive future mass production plans.
In 2024, ZENOMENON and EFFLORESCENCE, two colours designed by BASF and included in recent colour trends collections, were recognized by the Red Dot Design Award, one of the most prestigious design competitions in the world.
Zircotec’s research on ceramic coating development aims to enable the use of lightweight materials in electric vehicle battery housings and cooling plates.
Zircotec has secured significant government funding through the Advanced Propulsion Centre UK (APC) to develop a single proprietary ceramic coating that will unlock the use of lightweight materials, including aluminium, across EV battery enclosures and cooling plates. The battery cases of today’s electric vehicles are made of heavy-duty steel. Therefore, to reduce the weight of electric vehicles and improve their range, alternative, lightweight materials such as aluminium and plastic composites are required. Furthermore, the efficiency of aluminium cooling plates within the battery pack is hampered by the required electrical insulation and the typically low
level of thermal conductivity. It is possible to improve the efficiency of cooling plates by means of thin, high-performance electrical insulation with higher thermal conductivity. “The key to unlocking the use of new, lightweight materials across battery enclosures and cooling plates in EVs is being able to develop and effectively apply high-performance coatings that ensure the safe thermal and electrical operation of the substrate. The Advanced Propulsion Centre CeraBEV advanced route to market demonstrator project allows our engineers to develop world-first, all-in-one dielectric and flameproof ceramic coatings that will address and overcome the significant thermal
management and electrical insulation challenges associated with the lightweight materials OEMs want to use on their vehicles,” has commented Dominic Graham, Zircotec Engineering Director.
To realise the research, Zircotec will develop its existing range of ElectroHold® coatings to provide high-performance dielectric, flameretardant and EMC shielding properties. These products are lightweight, fit easily into existing automotive design infrastructures, protect against water ingress, corrosion and chemical attack, as well as provide maximum performance and adhesion levels during normal operating conditions.
“We’re delighted to be selected to receive this APC funding which will not only enable Zircotec to extend its current ceramic coating expertise within the EV sector, but will also accelerate the UK’s battery energy storage technology capability through ceramic coating research that has the power to transform material use in the battery electric vehicle sector,” has stated Andrew Donachie, COO of Zircotec.
“Our skills and experience in developing thermal management solutions for OEMs and top-flight motorsport, including F1, are well known. But the Electric Vehicle market is an area we’ve been focusing on heavily during the last 12 months by developing out our current thermal science so a new breed of ElectroHold® solutions. This proven technology will provide the platform for our work towards delivering the CeraBEV project,” has concluded Dominic Graham.
For further information: https://zircotec.com/
BASF provides its biomass-balanced ammonia BMBcertTM in order to reduce the product carbon footprint of Evonik's eCO label product range.
Evonik and BASF have recently announced a strategic partnership that highlights the commitment of both companies towards a sustainable economy and ambitious emissions reduction targets through products with a reduced product carbon footprint (PCF). BASF will in fact supply Evonik with its biomass-balanced ammonia BMBcertTM, a solution with over 65% reduction in PCF that will boost the production of the Evonik eCO label product range. Both companies are broadening their product portfolios by introducing ammonia-based products with a biomass balance approach, which are readily available via existing sales channels and fully integrated into the ERPEnterprise Resource Planning systems of both companies.
Evonik is planning to incorporate the ammonia BMBcertTM from BASF in the production of sustainable solutions such as the VESTAMIN® IPD eCO curing agents for epoxy resin systems suitable for industrial flooring, marine and anticorrosive paints and coatings, reflecting its aim to reduce CO2 emissions through a mass balance approach using renewable feedstocks as drop-in solutions in existing systems and manufacturing processes.
“We are excited to partner with BASF to source ammonia with a reduced carbon footprint for our eCO label products. This collaboration underscores our commitment to environmental stewardship and our ability to innovate in a rapidly changing market”, stated Silvia Torrado, Global Procurement Director for Base Petrochemicals at Evonik. BASF applies a biomass balance approach to replace fossil resources at the beginning
of the production process with certified biomethane from biowaste raw materials which are attributed to the product. The mass-balanced product is certified according to the IISCC (International Sustainability and Carbon Certification). In addition, the company is using electricity from renewable sources for manufacturing of the ammonia, further reducing its PCF.
By integrating the ammonia BMBcertTM from BASF into its ISCC PLUS certified production processes, Evonik demonstrates its commitment to a more sustainable economy and achieving its ambitious emissions reduction targets. As a matter of fact, it aims to reduce Scope 1 and 2 emissions by 25% by
2030 and Scope 3 emissions by approximately 11% from 2021 levels, targeting climate neutrality by 2050 – in line with the Paris Agreement and validated by Science Based Target Initiative (SBTi).
“Evonik and BASF share the same vision: we are convinced that the chemical industry can transform and replace fossil with renewable feedstocks and utilities. The supply with ammonia BMBcert is a big milestone for both of us”, added Jens Aßmann, Vice President of the value chain at BASF.
For further information: www.evonik.com
By establishing inaugural Scope 3 emissions intensity reduction goal and joining TfS Univar Solutions pursues more sustainable practices within its business and supply chain.
The international specialty chemicals manufacturer Univar Solutions LLC recently announced that it has advanced its actions to support sustainable practices through its supply chain: as a matter of fact, the company has established a Scope 3 emissions intensity reduction goal and launched EcoScope, a supplier collaboration programme focused on reducing Scope 3 emissions intensity.
The global Scope 1 and 2 emissions of Univar Solutions decreased by 19.9% from its baseline during 2023 and, in April of the same year, the company became a member of Together for Sustainability (TfS) – a joint initiative of chemical companies centred around advancing and aligning sustainability practices in the supply chain of the chemicals sector. The new goal of Univar Solutions is to reduce its Scope 3 emissions intensity by 15% by 2030 and achieve net zero emissions across all scopes by 2050.
“I am extremely proud of our progress in meeting our environmental commitments and I am also particularly excited about this next step in our journey. With our new goal of 15% intensity reduction in Scope 3 emissions by 2030 against a 2023 baseline, we are focused on driving sustainable practices forward and looking to deliver environmental value throughout our business and global supply chain. Our partnership with Together for Sustainability will play a crucial role in the success of our Scope 3 greenhouse gas emissions reduction efforts,” stated Alexa Colin, the general counsel at Univar Solutions.
By joining forces with fifty-two other specialty chemical and ingredient manufacturers and distributors to collectively promote sustainable changes and achieve ecological targets, the Together for Sustainability membership will allow Univar Solutions to strengthen data sharing and supply chain advancement in major areas, including broader value chain emission reductions and a chemical sector Product Carbon Footprint (PCF) Guideline.
“We found an excellent sustainability partner in the initiative: their exclusive focus on the chemical and ingredient industry enables us to access and share best practices among peer organisations and apply consistent methodologies on crucial sustainability issues, such as PCF. Many of our supplier partners are also members. Our membership will bring mutual benefits by fostering transparent and consistent processes and methods that collectively improve our sustainability results. Ultimately, we know that our customers seeking to source sustainably will benefit from our membership,” added Kelly Gilroy, the vice-president of Commercial Sustainability at Univar Solutions. “We also achieved the International Sustainability and Carbon Certification (ISCC) PLUS in Europe in 2023 and we are in progress for North America. These certifications are key to our strategy of supporting the transition of our supplier partners and customers to sustainable, traceable and deforestation-free supply chains. It covers supply chains for all kinds of biomass – including agricultural and forest biomass – biogenic waste and residues, nonbiological renewable materials and recycled carbon-based materials. By increasing our certifications of materials with sustainable attributes, we are helping to improve supply chain sustainability in the chemical industry.”
For further information: www.univarsolutions.com
MULTI-CHANNEL
GLOBAL ACCURATE ORIGINAL UP-TO-DATE UNIQUE
AUTHORITATIVE
Manuela Casali
UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy info@ucif.net
In 2024, ANIMA Confindustria opened an office within Confindustria’s premises in Brussels, aiming to represent, promote, and defend the interests of the Italian mechanical engineering industry at the main European institutions. This strategic step addresses the need for a physical presence in the heart of the European Union, a crucial hub for legislative development and the definition of the strategic lines that will guide innovation and growth in the European and Italian industrial fabric.
The ANIMA office in Brussels is not only an institutional base but an actual observation and coordination point on the main European dossiers of interest to the mechanical engineering sector. In an everchanging geopolitical and economic environment, its opening enables ANIMA to closely monitor legislative dynamics and be at the centre of decision-making processes that will influence the industry’s future. The office’s mission is also to act as a bridge between Italian companies and European institutions, creating a direct and constant dialogue with
the leading players involved in industrial and regulatory policy-making.
ANIMA Brussels, therefore, aims at promoting greater collaboration and strengthening the voice of the Italian mechanical engineering sector within European dynamics. It thus becomes a fundamental tool to ensure active and proactive representation of the Italian mechanical engineering industry in Europe, supporting it in future challenges with a constant presence and concrete commitment.
UCIF, the Italian Surface Treatment Equipment Manufacturers’ Association, and its member companies will benefit from being present through such representation in Brussels, thanks to a dedicated professional who will act as a “sentinel” reporting on the dynamics, challenges, and opportunities offered by the assignment of new political offices within the European Parliament.
This is a unique opportunity for Italian companies to be protagonists in the definition of future European industrial policies and strengthen their role in the international context.
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Considered one of the rarest colours in nature, purple has always been synonymous with uniqueness. Its duality – it is created by combining blue, a symbol of calm, with red, an emblem of passion – gives it a unique, evocative power. It represents good fortune and prosperity in the East but also power and black magic in the Western tradition, remaining steeped in history and mystery and capable of inspiring and fascinating even today.
Purple is a colour that has spanned the centuries, evoking complex emotions and conveying deep meanings. From delicate shades of lilac to intense tones of violet, it has been playing a role in many fields, from art to fashion, becoming a symbol of spirituality, mystery, and nobility. Rarely chosen by children in their drawings, it hides a history full of complexity and ambiguity that we often only fully understand in adulthood. A symbol of luxury and royalty in many cultures, it has also taken on darker connotations, being also associated with bad luck, death, and mourning. Its rarity in nature makes it an exclusive colour, imbued with an aura of preciousness. Created from the combination of blue’s soothing calm and red’s vibrant strength, purple can evoke different feelings depending on its shades, from spirituality and meditation to a sense of magic and transformation.
Besides its symbolic significance, it has also played an essential role in the history of pigments. In ancient times, obtaining a dye in this colour required complex and costly processes, such as extracting it from marine organisms, which helped cement its association with the upper classes. Even today, its chromatic complexity makes it a fascinating hue, capable of stimulating imagination and establishing itself as a distinctive choice in any context.
The origin of the word “purple”
This colour’s name derived from Latin purpura (indicating the same hue), which in turn came from Greek porphura (denoting the molluscs that yielded a dye in this tint and the fabric dyed with it). The name of one of its shades, violet, similarly to purple’s name in other languages (viola in Italian and violet in French – morado in Spanish has a different history linked to moras, “blackberries”), derived from Latin viola, from the flower that grows wild in temperate climates. Its etymology, which goes back to the Indo-European root wi- (meaning “to bend” or “to turn”), recalls the transition between red and blue, symbolising this hue’s elusive and mysterious nature.
Purple in history:
from an exclusive symbol to a popular colour
The history of purple is as fascinating as it is rich in meaning and transformation. Associated with royalty, spirituality, and mystery, this colour has spanned the millennia, linking itself to cultures, religions, and artistic movements.
It has its roots in ancient times, when Tyrian purple, a dye obtained from thousands of molluscs, was the ultimate symbol of luxury, power, and royalty. About 12,000 molluscs were needed to obtain just 1.5 grams of dye, making purple exclusive to the elite. Roman emperors such as Elagabalus made it an emblem of their power, whereas the founder of
the Persian Empire, Cyrus the Great, adopted it as his personal symbol in the 6th century BC.
In Christianity, purple acquired profound connotations. Around 1200, Pope Innocent III designated it as a symbol of penance, and it became the official colour of the clergy during the liturgical seasons of Advent and Lent. Catholic and Anglican bishops still have purple in their vestments today. In modern times, this hue has continued to play a similarly important role by being worn by scholars and university professors to communicate authority and wisdom.
For centuries, its production remained complex and expensive until a breakthrough in 1856: a young British chemist named William Henry Perkin, while attempting to synthesise quinine, accidentally discovered a deep purple dye that he called mauveine. This event marked the creation of the first synthetic dye and revolutionised the world of chemistry. Perkin industrialised the process, making purple accessible to all – and turning it from an exclusive symbol of luxury to a mass colour.
The role of purple in art and corporate communication
Purple has always fascinated artists because of its ability to evoke complex emotions. In visual arts, dark purple is often associated with elegance and luxury, whereas lilac and lavender are linked to tranquillity and calm.
About 12,000 molluscs were needed to produce 1.5 grams of Tyrian purple.
From left to right:
Nymphéas bleus, 1916-1919. Claude Monet.
Purple is also one of the protagonists of Van Gogh’s famous starry skies.
Service provider Yahoo! uses this colour to convey strength and mystery.
Swiss chocolate producer Milka has been using the colour violet since 1901 to symbolise sweetness and quality.
In the 19th century, the introduction of cobalt violet enriched the painters’ palettes, opening up new expressive possibilities: initially toxic, this pigment was later improved, becoming a key element for artists such as Paul Signac, the master of Pointillism, who used purple shades to create colour harmonies in his landscapes. Claude Monet, the father of Impressionism, used violet to lend depth and mystery to his iconic water lilies; the series “Les Nymphéas”, shown in major exhibitions in Paris and New York, is testimony to this. Purple is also found in Vincent van Gogh’s masterpieces, including his famous depictions of irises and starry skies, where he combined it with complementary yellow to create exciting and vibrant contrasts. Known for its ability to attract attention and convey deep emotions, this colour has been used not only in art but also in design to communicate sophistication and originality. Therefore, it is not surprising that many successful brands have chosen purple as a distinctive element of their visual identities, harnessing its evocative power to create a strong connection with the public. In corporate communication, this hue is the protagonist of numerous brand images. Service provider Yahoo! uses it to convey strength and mystery. Swiss chocolate producer Milka has been using it to represent sweetness and quality since 1901. Transport company FedEx’s logo combines purple with orange to emphasise the concepts of innovation and professionalism, whereas its iconic white arrow is a masterpiece of graphic design. Taco Bell distinguishes itself in the fast food sector with purple, evoking comfort and originality. LA Lakers pair it with yellow as a symbol of courage. Finally, airline Wizz Air relies on this colour to communicate affordable luxury even on low-cost flights.
With its duality, poised between sophistication and eccentricity, purple has always been a distinctive choice in the fashion world. Ever since the Victorian era, when
synthetic dyes such as mauveine allowed it to become more widely available, it has established itself as a symbol of luxury and social status. Internationally renowned fashion designers such as Valentino, Versace, and Alexander McQueen have used purple in iconic collections to evoke elegance and an aura of mystery.
While deep shades such as violet and aubergine express royalty and opulence, lighter shades such as lavender or lilac communicate romanticism and delicacy. At the same time, purple has also been associated with an aesthetic of rebellion and nonconformity: in the 1970s, it was a central element of the glam rock style, adopted by artists such as David Bowie and bands such as Queen. In recent years, it has become an emblematic colour for fashion shows aiming to break with conventions and surprise, bringing a feeling of avant-garde and innovation. Purple, therefore, is a versatile choice for designers, capable of communicating sophisticated luxury or creative rebellion depending on the context while always maintaining a strong visual impact. It continues to star on catwalks and red carpets, representing a style that combines tradition and modernity.
Besides visual arts, purple has profoundly influenced popular culture, taking on different meanings depending on the context. In music, it has become an emblem of sensuality, rebellion, and experimentation thanks to icons such as Prince, whose “Purple Rain” is not only a style manifesto but also a symbol of introspection and passion, and Jimi Hendrix, who turned this colour into a psychedelic and
visionary symbol of the 1960s counterculture with his “Purple Haze”. In film and literature, purple is associated with mystery, magic, and emotional introspection. In the dreamlike landscapes of “Alice in Wonderland”, it embodies the surreal and the fantastic; in futuristic settings of science fiction films such as “Blade Runner” or “Dune”, it represents advanced technology, alienation, and enigmatic beauty. Purple also frequently appears in fantasy films, such as the “Harry Potter” saga, often linked to magic potions, spells, and settings related to the unknown. It has also found its way into animation: think of iconic characters such as Maleficent from “Sleeping Beauty”, whose use of purple conveys an idea of power, darkness, and mystery, or the Cheshire Cat, whose enigmatic smile and purple shades accentuate its unpredictable and magical nature.
Finally, in video games, purple is often used to represent magical powers, cosmic energy, or particularly charismatic characters, such as Mewtwo in “Pokémon” or Thanos in the Marvel Universe, who combines superhuman strength with psychological complexity. In other words, this colour confirms itself as a many-sided element, capable of representing sensuality, rebellion, mystery, and imagination in all forms of pop culture.
In European and Western cultures, purple has had mixed meanings, both positive and negative. For centuries, as mentioned, it was associated with royalty and nobility, a symbol of wealth and prestige, especially during the Middle Ages, when purple pigments were
expensive and difficult to obtain. However, purple also had darker connotations. In some traditions, its use on particular occasions, such as during times of mourning, was seen as bringing bad luck. Moreover, in popular culture, purple was sometimes associated with the devil and black magic, fuelling its connection with the unknown and the mysterious. In Christian symbolism, it was worn by priests during Lent and Advent, in the context of penance and spiritual meditation. In some Western cultures, moreover, purple is one of the colours avoided at weddings, along with white and black, because it is considered a symbol of sadness or infidelity. In fashion and television, it was sometimes perceived as a colour that brought bad luck, although today, it is used for elegance and originality.
In China, the perception of purple was peculiar. During the Han dynasty, it was not a commonly used colour and was considered relatively rare. However, in the ceramics and paintings of the time, it appeared as a symbol of an evolving art and a particular aesthetic sense. Its rarity and beauty made it fascinating, but it did not enjoy the same popularity as traditional colours such as red or yellow, which had stronger connotations of prosperity and good fortune. In brief, while appreciated, purple was not viewed with the same degree of veneration as other tints but rather perceived as a choice to detach from established traditions. In Japan, purple acquired a meaning of great refinement and social status during the Heian period (794-1185). The pigment murasaki, extracted from the alkanet plant, was used to dye fabrics and paint and became a symbol of Japanese nobility. Its association with high social classes made it a favourite colour in the imperial courts, and even in the classics of Japanese literature, including “Genji Monogatari”, purple symbolised elegance and prestige.
In Thailand, on the other hand, purple has a very different meaning. It is closely associated with mourning and used by widows and other people as a sign of respect for the dead. Here, this colour represents grief and remembrance, and it is chosen during times of mourning as a symbol of sadness and respect for death. In this context, it takes on a meaning of reflection and commemoration, far from its association with royalty or luxury typical of other cultures.
Transport company FedEx’s logo combines purple with orange to emphasise the concepts of innovation and professionalism, whereas its iconic white arrow is a true masterpiece of graphic design.
In the case of Maleficent, the antagonist of Sleeping Beauty, purple represents power, darkness, and mystery.
In Japan, the pigment murasaki was extracted from the flower of alkanet (Alkanna tinctoria) and used to dye fabrics and paint.
Global Industrie will take place from March 11th to 14th 2025, at Eurexpo Lyon (France).
Global Industrie is the annual marker for the industry’s achievements, progress, vision and future prospects, and is the event that brings together those who make up today’s industry and will do so tomorrow. Through specific highlights, this meeting is a territory of expression where everyone can present their innovations, exchange ideas, challenge each other and be inspired by industrial trends and current events.
The renewed presidency of Nicolas Dufourcq, CEO of Bpifrance, also confirms Global Industrie’s official status as the expression of French industry. Together, they bring together all those involved in the drive to rehabilitate and renew industry.
From March 11 to 14, 2025, at Eurexpo Lyon (France), Global Industrie will be the voice of this sector and the showcase for solutions for all industrial sectors. 50,000 professionals are expected to attend.
As the driving force behind innovation and growth, the human factor will be the main theme of this year’s event, 2025. It’s an opportunity to bring back to the forefront the people who are at the source of industrial, digital, environmental and societal transformation, as well as the inventors of the professions of the future.
To illustrate this theme, Global Industrie will be welcoming inspiring personalities (top business leaders, personalities from the world of industry...), highlighting the initiatives taken by men and women in the regions and in the factories, and offering spaces to share with the younger generation and thus consolidate the industry of tomorrow. Over 800 speakers are expected to take part in 2025.
On the Main Stage, the major issues that will shape the industry of today and tomorrow will be debated, issues will be presented, and know-how, innovations and best practices will be shared...
The Global Industrie TV platform will showcase the skills, talents and uniqueness of all the manufacturers present.
The GI Avenir area will help to raise awareness among future industry players by introducing them to the industrial fabric, the sectors, the professions... With over 6,000 young people and job seekers in attendance in 2024, Global Industrie will once again confirm its role as a key platform for promoting the attractiveness of industrial professions.
Immersive, experiential immersion in French industry
Global Industrie is the only event in France to bring together the entire industrial sector, its ecosystem, value chain and end-user markets.
A showcase for know-how and an expression of talent, the show presents the innovations of 2,500 exhibitors grouped together in 14 universes to provide visitors with concrete solutions and meet the challenges of the industrial renaissance, whether economic, ecological or sovereignty related. Global Industrie is thus a major cog in the wheel and an anchor point for this dynamic, offering a unique opportunity to monitor emerging trends and signals in a single venue, to better anticipate transformations in industry. In 2025, visitors will discover, among other things:
5G/IA/cybersecurity village
Today, data is at the heart of industrial strategy, enabling us to manage, optimize and make industry even more competitive and resilient. For the first time, a village will bring together the 3 key players in data: 5G, which provides increased connectivity to facilitate the transmission and sharing of data; AI, which enables data to be analyzed and put to good use; and cybersecurity, which secures all this information. This village will help to acculturate companies to this digital transformation by raising their awareness of the new uses of private 5G, new technologies and laws linked to cybersecurity and artificial intelligence.
Handling, storage, logistics and lifting village
The handling, storage, logistics and lifting quartet is an essential tool for reindustrialization. By optimizing these key areas, they generate significant productivity gains in automated inventory management, automated production, order preparation, multiple robotized applications and all the equipment and tools required for these functions. For the first time, Global Industrie will be featuring a specific section dedicated to supply chain improvement solutions that help to reduce costs and increase productivity, anticipate market fluctuations and improve the value chain.
A crucial issue for any modern industrial company, safety and well-being at work (QWL) protect employees’ mental and physical health and improve productivity and the company’s reputation. This new village will bring together companies working to improve working conditions through solutions and advice that reinforce the company’s safety culture. Issues such as stress, ergonomics, training, standards and technologies to combat musculoskeletal disorders (MSDs) will be addressed...
In addition to these first new products, the 14 universes on offer at the show will cover all construction, manufacturing and industrial production processes.
For further information: https://global-industrie.com
Current major challenges, but even greater prospects for the future: Aluminium continues to be a key enabler across a variety of industries. The positive sentiment in the international aluminium industry was clearly evident at ALUMINIUM 2024 in Düsseldorf.
With 20,904 visitors from 99 countries (2022: 18,600) and 819 exhibitors and partners from 50 nations, ALUMINIUM brought together industry players along the entire value chain from 8 to 10 October 2024 – from raw material suppliers to producers, processors and recycling experts. “Optimism and confidence were the defining feelings at ALUMINIUM 2024, despite the various challenges in the individual markets,” said Michael Köhler, Managing Director of RX Deutschland GmbH, the event organiser. “Aluminium remains a crucial factor in the future of many industries worldwide, particularly in the context of decarbonisation. As the leading global event, we are not just a platform; we are a vital driver of innovation and progress.”
Despite concerns over energy supply, supply chains, and global competition, ALUMINIUM 2024 demonstrated that the industry is in a strong position. “Despite the current challenges, we remain optimistic,” said Rob van Gils, President of the Aluminium Deutschland association. “If we create the right framework conditions, the aluminium industry in Germany and Europe has a bright future ahead.” According to van Gils, this includes “competitive conditions and planning security, especially in energy supply. A European Industrial Deal is urgently needed to safeguard the competitiveness of European companies.”
Paul Voss, Director General of the European Aluminium association, also emphasised that EU industrial policy is a crucial lever for fostering innovation and decarbonisation. “The good news is that the political framework is already changing. And the aluminium industry has the solutions needed to actively shape this transition,” Voss stated during the ALUMINIUM press conference.
Aluminium as a key component of industrial transformation
In Germany, the government has also recognised the importance of the aluminium industry and the material itself. “The aluminium industry is a vital part of the future for both Germany and Europe,” said Dr Robert Habeck, Federal Minister for Economic Affairs and Climate Action, in his video message at the opening of the event. “Aluminium is practically ideal when it comes to industrial transformation, lightweight
construction, competitiveness, and decarbonisation.” He added, “We are working intensively on further improving our location, particularly regarding energy costs, reducing unnecessary bureaucratic burdens, and strengthening fair competition.”
Global growth opportunities
Exhibitors also reflected the optimism within the industry: “There’s a great atmosphere and energy, and it’s important for the industry to come together and celebrate our fantastic material,” said Antti Laakkonen from Constellium.
While it may take some time for this celebratory mood to reach all markets and sectors, the outlook remains positive. “Markets are slowing down slightly due to the global crisis and recessions in some regions. But growth will certainly come over the next few years, even if it might be less and slower than previously expected,” explained Michael Schaefer from SMS group.
This also applies to the automotive industry, a key market that is currently not fully meeting the expectations of recent years. “The automotive sector is certainly facing challenges at the moment, particularly in e-mobility. Customers are hesitating with their decisions. They’re unsure whether they should buy an electric vehicle or not. But e-mobility is coming, that’s for sure. The only question is when. It has already gained importance and will continue to grow, albeit slightly behind the expectations from months or years ago. But it will come, and it represents enormous growth potential for aluminium,” said Pascal Wagner from Speira.
Beyond the automotive sector, expectations for a recovery in other markets remain high. “I believe the vehicle and construction markets will make a comeback,” Michael Zint from the apt group confidently stated.
The demand for aluminium is being driven by sustainability efforts across almost all global industries. “We see a strong substitution of copper and steel with aluminium. Our long-term outlook is quite positive, as aluminium is a crucial contributor to the green, sustainable transformation,” said Marijn Rietveld from Norsk Hydro. Aluminium’s recyclability is a key factor in this, with the material benefitting greatly from its circular potential. “The more circular the industry becomes, the more development there will be. And, of course, Europe is leading the charge towards a stronger circular economy. I think this is a very important development for the aluminium industry as a whole,” added Derin Akersoy from Assan Alüminyum.
Supply chains remain a central issue in the context of globalisation: “I see growth on a global level. What we’ve seen is that there are essentially two macro drivers supporting this growth. The number one is sustainability. We could also see a clear trend that it is important to deliver globally but with local, regional supply chains,” noted Frederik Spens from Gränges.
ALUMINIUM 2024 was not just a platform for professional exchange but also for networking and business deals. “The exhibition is an opportunity for us to meet with our customers, suppliers, and business partners.
This morning, we signed a very ambitious contract with our business partner. And ALUMINIUM is the platform to do something like that,” said Alexandre Gellert from Novelis after a successful day at the event.
But it wasn’t just new business that was initiated at ALUMINIUM; the event also set important impulses for the economic and societal development of the industry. Topics such as the shortage of skilled workers and recruitment of young talent were high on the agenda to attract the next generation to the aluminium industry. The premiere of the “Women With Metal – the ALUMINIUM Awards” also sent a strong signal for more visibility and recognition of women in the industry, marking an important step towards greater diversity within the sector. “This year’s event clearly showed that the aluminium industry and its material play a crucial role in solving many of the world’s global challenges,” concluded Michael Köhler. “The exchange at ALUMINIUM 2024 was urgently needed. The industry has a lot to discuss. We will continue to support this dialogue as a platform and pick it up again, at the latest, at the next ALUMINIUM event in 2026.”
For further information: www.aluminium-exhibition.com/en-gb.html#/
Surface Design Show is the event of choice for architects and designers. The exhibition takes place annually, and next year it will be held from 4 to 6 February 2025 at The Business Design Centre in Islington, London.
Surface Design Show (SDS) reveals its 2025 theme: Creative Conscience. Taking place 4-6 February at London’s Business Design Centre in Islington, this years’ event will highlight the future of materials for the built environment, focusing on sustainability, technological advancement, and the human experience.
Creative Conscience embodies a drive and commitment to sustainable, ethical, and innovative design. This forward-thinking attitude explores the harmonious fusion of colour, sustainability and ingenuity in surface design for architecture and interiors. Harnessing creativity while encouraging meaningful connections to the world around us, designers can offer more sophisticated, adaptable, and user-centric solutions. Creative Conscience not only enhances functionality and aesthetics but also promotes a deeper connection to sustainable living.
“The intersection of design trends, technological advancements, and sustainability will be celebrated in our 2025 edition. The theme focuses on the future of materials for the built environment driven by developments in technology, a heightened focus on sustainability, and a deeper understanding of human needs” – said Nickie West, SDS Managing Director.
Located right in the centre of the Show, Surface Spotlight Live (SSL) features ground-breaking materials for visitors to touch and feel, giving a truly ‘hands-on’ experience for architects and designers to enjoy and learn from. Curated by trend expert Sally Angharad, SSL presents a selection of surfaces, finishes and materials that celebrate the power of creative thinking, demonstrating how ethical innovation is providing positive design solutions.
Over the course of the show, the theme will be present on the main stage as part of the speaker programme. With over 50 speakers making an appearance during the show, several sessions, including the Opening Night Debate will focus on the topic of Creative Conscience giving key insights into the future of materials within the built environment.
For further information: www.surfacedesignshow.com
Deburring, surface nishing and industrial parts cleaning becomes
www.parts- nishing.com
+ AGTOS Gesellscha für technische Ober ächensysteme mbH + BOUS RENZMANN Cleantech GmbH + C. Hilzinger-Thum GmbH & Co. KG + plasotec GmbH + Karl Roll GmbH & Co. KG + MAFRA MAILE GMBH + OTEC Präzisions nish GmbH + PERO AG P. Erbel Maschinen- und
Apparatebau + Rösler Ober ächentechnik GmbH ... When do you register?
November 12-13, 2025 · Messe Karlsruhe
Kyzen showcased its innovative and sustainable cleaning chemistries like aqueous cleaning agents, vacuum degreasing solvent cleaners and solvent replacements at the latest edition of Fabtech, the international trade fair dedicated to metal forming, fabricating, welding and finishing that took place from 15th to 17th October 2024 at the Orange County Convention Centre in Orlando (Florida, United States of America).
Founded in 1990, the company is a global manufacturer and distributor of environmentally-responsible and RoHS-compliant precision cleaning chemistries employed by several industrial sectors, ranging from electronics and advanced packaging to metal finishing and aerospace applications. At the event, Kyzen then showcased its cleaning technologies and provided technical customer support, offering insights and solutions for different challenges, such as cleaning and protecting parts from corrosion with a single chemistry, improving remanufacturing and vacuum degreasing processes or replacing solvents that may soon be
completely banned, in light of recent EPA restrictions and the current phasedown in production of materials containing PFAS and HFCs.
As a matter of fact, its award-winning products are designed to effectively remove a variety of oils, coolants, smut, and oxides from many substrates in precision metal cleaning applications. During Fabtech, visitors were able to discover chemistries for cleaning and brightening brass, protecting aluminium, and removing carbon smut from deep drawn steel
For further information: www.kyzen.com
For years, Fismet Service has been a benchmark supplier in the industrial cleaning sector, acting as a partner for both system design and contract services. At the heart of this company are innovation and sustainability with a unique approach to industrial cleaning, as confirmed by its founder and owner, Sabino di Pierro.
The importance of cleaning industrial components should never be underestimated. In fact, it is a critical element in the success of any production cycle. An effective cleaning process directly affects the quality of end products, especially in critical stages such as coating, PVD treatment, or sputtering. At the same time, each component has specific contaminants that require a customised approach to ensure optimal results. A specially designed cleaning cycle is thus essential not only to remove such residues effectively but also to ensure higher quality standards, minimising the risk of defects and optimising the entire production process. To explore these issues in detail, we interviewed Sabino di Pierro, the founder and owner of Fismet Service Srl (Cornaredo, Milan, Italy), who shared his vision of customised industrial cleaning processes and some of his company’s innovative projects.
ipcm®: Fismet is known for its unique, almost ‘medical’ philosophy based on providing a specific treatment for each component. Can you explain how this vision came about and how you apply it?
Sabino di Pierro: “Our philosophy stems from the realisation that each component has unique characteristics, just as each contaminant requires specific treatment. At Fismet, we have always approached each cleaning project as a ‘clinical case’ and the contaminated object as a kind of ‘patient’. For us, every workpiece, every surface, and every contaminant requires tailored action. It is as if each part had its own ‘disease’ to be treated with the utmost care and precision. This approach translates into the choice to offer a highly customised service: we never use standardised processes because we believe that carefully analysing the individual case is indispensable to achieving flawless results. After identifying the type of surface and contaminant, we design an ad hoc cleaning cycle. Finally, we perform rigorous analyses and checks at the end of the process to validate its effectiveness and ensure that the required quality parameters are met. This enables us to achieve a very high level of quality but also to minimise waste and environmental impact.”
ipcm®: Contract cleaning is one of your most popular services. What benefits does it bring to companies, and why is it so innovative?
Sabino di Pierro: “We created this dedicated division to meet some customers’ need to delegate the cleaning process and avoid worrying about plant management, maintenance, or disposal operations. We offer them an advanced equipment fleet and a turnkey service, complete with a clean room and test laboratories where cleaning cycles are customised and closely monitored. That ensures a consistent, smooth, high-quality service at a fixed cost and with guaranteed delivery times. We aim to relieve companies of any hassle by providing superior and safe cleaning quality.”
ipcm®: Sustainability is a core value for Fismet. How is it implemented in your daily work?
Sabino di Pierro: Sustainability is not just a choice for Fismet: it is a duty we embrace firmly. For years now, we have been working to reduce resource consumption and improve the efficiency of our processes, using technologies that respect the environment and the health of operators. In line with the circular economy principles, which are finally catching on in the industry as well, our aim is to turn what was previously considered ‘waste’ into a useful resource. For instance, we have developed solutions to clean not only industrial parts but also production tools and accessories, such as moulds and containers, which often end up as waste once soiled. By recovering and reusing these devices, we extend their life cycle and reduce the waste to be disposed of. This approach reduces costs for our customers and, at the same time, allows using less water and chemicals, making our cleaning processes more sustainable. And that is not all: our research team constantly works to find new ways to minimise environmental impact and
optimise efficiency. In short, every decision we make at Fismet aims to reduce waste, minimise consumption, and lower the polluting impact of industrial activities.”
ipcm®: Your latest project involves the inspection of processes on both older machines and new systems. How was this idea conceived, which you summarised with the word ‘prevention’, and what advantages does it offer companies?
Sabino di Pierro: “Through this check-up, we provide companies with the tools to optimize their process choices, ensuring not only compliance with the quality standards required by various specifications but also adherence to safety regulations, while reducing pollution and minimizing waste production and disposal. This service addresses the need for a more sustainable industry and helps to limit resource waste”.
ipcm®: How do you see the future of Fismet Service, and what are its next challenges?
Sabino di Pierro: “Fismet’s future revolves around constantly innovating and reducing the environmental impact of industrial processes. We are constantly looking for new, more sustainable cleaning technologies and are working on systems that can reuse waste materials. Many challenges await us, but we aim to keep pace with industrial evolutions to act as a partner capable of meeting its customers’ needs while anticipating the trends of an increasingly sustainability-conscious market. Additionally, we are creating a new clean room designed to perform cleaning processes directly inside, unlike the current one, which is used only for cleaning tests. In the first quarter of next year, this clean room will be operational and connected to multiple cleaning machines, ensuring superior results.”
Roll-to-roll production lines enable printed photovoltaic modules to be produced particularly cost-effectively. To avoid short circuits, however, conductive burrs created when the front electrode is laser structured previously had to be removed manually in a way that was not compatible with the industrial process. In a joint project, a fully automated CO2 snow-jet cleaning solution was developed that can be integrated into the production line to eliminate this problem.
With a layer thickness of between 0.5 and one micrometre and high efficiency even when solar radiation levels are low, flexible, printed photovoltaic cells open up a wide range of applications when it comes to supplying solar energy. In the field of printed photovoltaics, the roll-to-roll process offers major advantages in terms of production speed, volume and costs. The five layers of the modules, which are based on organic and perovskite semiconductors, can be processed individually.
The bottom layer - a transparent IMI electrode (structure: indium tin oxide, silver, indium tin oxide) - is structured by laser. Burrs are formed along the structured edges, which are conductive and protrude a few
micrometres from the surface. If they are not removed, they will cause damage and short circuits due to the thinness of the modules. The current practice is to remove the burrs mechanically at very low web speeds. However, there is a risk of the structured layers becoming damaged due to the mechanical impact.
To solve this problem when manufacturing printed photovoltaic modules on roll-to-roll production lines, the Institute Materials for Electronics and Energy Technology (I-MEET) together with the Solar Factory of the Future at Friedrich-Alexander-Universität Erlangen-
Nürnberg, Sciprios GmbH1 and acp systems AG, initiated the “PV-CO2” research project funded by the Federal Ministry for Economic Affairs and Climate Action (BMWK). The aim was to develop a fully automated CO2 snow jet cleaning system for industrial use based on acp’s quattroClean snow jet technology. This is a dry process which is used for full-surface and selective cleaning applications. The cleaning medium is liquid carbon dioxide recycled from chemical production processes and energy generation from biomass. The carbon dioxide is guided through a wear-free two-substance ring nozzle and expands on exiting to form fine snow crystals. These are bundled by a separate jacket jet of compressed air and accelerated to supersonic speed. When the easily-focused jet of snow and compressed air impacts on the surface to be cleaned, a combination of thermal, mechanical, solvent and sublimation effects occur, which is the basis of the cleaning action. The crystalline carbon dioxide sublimates completely during the process, leaving the treated surfaces completely dry.
A roll-to-roll pilot line was set up for cleaning the laser-structured electrode substrates and fitted with several quattroClean snow jet nozzles arranged above the electrode web. The first step was to optimize the jet parameters so as to significantly reduce the burr height without damaging the electrode. In addition to the capillary diameter, which determines the flow rate of the liquid carbon dioxide, and the pressure of the compressed air jacket, the distance between the nozzle and the substrate needed to be adjusted, as well as the web speed and the inclination of the nozzles in relation to the substrate. After each cleaning process, the maximum burr height was measured by confocal microscopy.
1 www.sciprios.de
This procedure was repeated for a large number of parameter combinations until an optimum cleaning result was achieved. To evaluate how deburring affects photovoltaic efficiency, organic photovoltaic modules eight centimetres wide were produced on substrates that had been cleaned using the CO2 snow-jet process. These were compared with modules produced on untreated substrates and manually-cleaned substrates of the same size. As expected, the modules on the uncleaned substrate had a high leakage current, which reduced Photovoltaic Cell Efficiency (PCE) to 2.3 %. For the manually cleaned modules, the PCE was 4.8 %, and for the modules cleaned using the CO2 snow-jet process, it was as high as 5.3 %. The difference in efficiency is explained by the fact that manual cleaning causes scratches to be formed on the electrode, which can significantly reduce the active area. This is because the scratched area does not generate any current and also because areas can be cut off from the charge extraction by the scratch. Dark Lock-In Thermography (DLIT) was used to confirm that
Advanex has expanded its range of MecWash cleaning systems with a new machine for its metal and plastic components, threaded inserts, springs, and assemblies, integrating the MWX400. This system was designed to be a versatile workhorse for engineering sectors that require high standards of cleanliness.
Advanex Europe has reported its latest leap forward in component cleanliness after its purchase of a MecWash MWX400. Advanex has bought three parts washing systems since initially speaking to the MecWash team at the MACH exhibition in 2012. The upgrades have been required to meet capacity increases and strict requirements of its customers.
“Each of the machines we have purchased from MecWash have provided us with a leap forward in efficiency. The MWX400 has made a substantial difference in the volume and speed of the parts washing at Advanex.
The previous MecWash machines exceeded our expectations and the MWX400 has done exactly the same,” said Rob Newham, operations manager at Advanex.
Alan Atkinson, sales manager at MecWash, said: “We were delighted to be chosen to supply another high specification, high volume parts washing machine. Working with Advanex over the last 12 years has provided our team with a detailed understanding of their cleaning requirements. Choosing the optimum parts washing system was crucial for Advanex to provide consistent component cleaning.
“Many of the products made by Advanex are very delicate, so it is vital the cleaning and finishing process does not cause any damage. We previously worked alongside Advanex to create a bespoke wash chemical formulation for its application. The solution was designed to clean and protect the sensitive components and produce a bright
finish. Our machines are some of the most sophisticated, connected parts washing systems in the world and the MWX400 features remote servicing, fault diagnosis, maintenance and management.
“The team at Advanex understand the reliability and cleaning capability generated by a MecWash industrial parts washer. The MWX400 is the most appropriate system to meet the demands of the increased workload and is designed to process the most intricate machined or pressed parts that require the highest standards of cleanliness, finish and dryness,” said Atkinson.
Advanex Europe is the European Headquarters of the global Advanex Group which has more than 20 operations worldwide. Advanex specialise in metal and plastic components, thread inserts, springs and assemblies, supplying a diverse range of markets, namely medical, aerospace and automotive.
The precision engineering firm bought their first MecWash cleaning system, the AVD 300, to replace an ultrasonic tank system. In 2018, Advanex bought a Duo from MecWash to ensure that the increased levels of demand, and the high-level standards of the cleaning and drying of their complex and intricate machined coiled or pressed medical parts continued. Since then, the business has grown substantially as demand for their quality medical products has increased, thus the need for a continual improvement in cleaning productivity over the last decade.
The cleaning capability of all the MecWash systems has impressed Rob Newham, who understands the importance of regulatory adherence for his customers.
“The MWX400 is the most advanced of the MecWash machines, and as a long-time customer, it was the best choice to satisfy our high-volume production requirements. The machine meets and surpasses our requirements and more by giving a controlled, validated outcome on each cycle,” explained Rob Newham.
John Pattison, managing director of MecWash, said: “The purchase of the MWX400 and the continued relationship with a loyal customer such as Advanex is further proof of the effectiveness of a MecWash system.
“We have a proud history of repeat business due to the excellent cleaning standards that our industrial parts washing systems provide. Our engineers design and build the systems to tackle the most difficult industrial cleaning challenges from across manufacturing. We work closely with our customers throughout all stages of the manufacturing to ensure we achieve the best results possible, rather than ‘one size fits all’. This approach has resulted in a large number of long-term relationships with our customers. “Customers trust us because we take the time to understand their needs and continue to provide support to them throughout the product life cycle. Investing in a MecWash system generates significant benefits for manufacturers, with measurable improvements in cleanliness and productivity,’ concluded Pattison.
For further information: www.mecwash.com and https://advanex.co.uk
As
The SySPOT research project, which involves 14 consortium partners, including HÖCKH Parts Cleaning Technology, aims to develop an assistance system that provides users with real-time information about the properties of particles and their formation, combined with a self-configuration of the cleaning system.
As industrial parts cleaning is becoming increasingly complex, new economical solutions are required. This is why the research project SySPOT utilizes artificial intelligence (AI) to optimize processes and use resources more efficiently. The goal is to develop an autonomous cleaning system that can automatically adjust the cleaning process. A total of 14 consortium partners, including HÖCKH Parts
Cleaning Technology, are involved in the SySPOT research project that aims to develop a system for adaptive photonic surface testing with image evaluation in combination with a cleaning system. As a first step, the companies and research institutes involved in the project, have identified the basic requirements for the overall system and developed algorithms for automatic image capture and sensor self-configuration.
Before the cleaning process, a newly developed sensor analyzes the workpiece using video inspection and particulate analysis to determine the degree of soiling and choose the appropriate cleaning program.
The sensor is equipped with lights that are arranged in several concentric rings, enabling it to illuminate the parts from different angles. This reveals more than just soiling, as scratches and fingerprints, that often only become visible during the parts cleaning process, are detected as well. Based on the type of contamination and specific customer requirements, the parts are then categorized as OK or NOK. Throughout the project, the consortium partners have further developed the initial idea of letting the sensor make autonomous decisions. A rating scale based on German school grades from 1 (Very Good) to 6 (Insufficient) acts as a learning help for the AI. The system detects the human input and adjusts its algorithms accordingly to
achieve optimal cleanliness. The goal is for the AI to eventually reach cleaning quality grade 1 and continuously improve the cleaning process.
A significant advancement was made by integrating edge devices to control the cleaning system. The SySPOT project uses Raspberry Pi microcomputers to process the data locally before it is transferred to the cloud. The local edge devices ensure fast and efficient data processing, and are an interface to the cloud, where the data is used to further train the AI. At the same time, the consortium partners are continuously improving the AI models and sensor integrations that provide data for the AI.
The overall system has advanced to the point where users can define specific instructions for cleanliness, and the AI can suggest one of four currently available programs: Perfect Cleanliness, Good Cleaning, Standard Cleaning, and Intermediate Cleaning. Furthermore, the AI can
make predictive suggestions, such as when to change the bath, and point out potential faults. For example, when filters need to be replaced too often, this could indicate a more fundamental problem.
HÖCKH Parts Cleaning Technology has provided extensive live data as well as a database of cleaning parameters and results for the project. This data also contains the changes that have led to the desired results. The database is used to train the AI, and it is complemented by the extensive experience and knowledge of experts from HÖCKH, who significantly contribute to the development and optimization of the cleaning processes. Despite the project’s significant progress, developing a complete self-configuration and process adjustment for the cleaning system has turned out to be more complex than originally anticipated. The consortium partners are therefore planning to apply for additional research funding to continue development and finish the project. An important milestone will be the integration of AI algorithms into the daily workflow, providing an automated and adaptive parts cleaning process.
While a final assessment of the value of AI in the daily workflow can only be made after the follow-up project has been completed, users can be optimistic that AI will significantly improve parts cleaning processes. The benefits of AI include a more efficient usage of resources and lower costs while adhering to high cleanliness requirements. Even the most demanding cleaning processes could be completed with a minimal use of resources thanks to continuous adjustments and optimizations made by the AI.
The SySPOT project highlights how AI can significantly improve parts cleaning. Even though there are still some challenges, and further development is required, it is safe to say that, in the future, AI will play a key role in the optimization of cleaning processes. Experts can look forward to seeing how further developments will progress and what specific improvements can be achieved in practice. An autonomous, selfconfiguring cleaning system could change industrial parts cleaning and set new standards for parts cleanliness.
HÖCKH has equipped a cleaning system with numerous sensors for the SySPOT research project.
The manufacturer was looking for a suitable method to clean the inner surfaces of an oil pressure line containing an elastomer part sheathed in metal mesh. The decisive factor in favour of the dry quattroClean snow jet technology was the consistent compliance with the cleanliness specification of “no particles larger than 400 micrometres” and also the fact that no waste water is produced during the dry cleaning process.
The first metal hose was invented in Pforzheim back in 1885 by the jewellery manufacturer Heinrich Witzenmann, together with the French engineer Eugène Levavassèur. This robust and flexible product was based on the model of the goose neck necklace. Witzenmann continued to develop all noteworthy profiles for hose production which are still of technical significance today. Further developments followed, such as the mechanically corrugated metal hose, metal bellows and axial expansion joints. Today, the family-owned company is the world’s leading manufacturer of these flexible metallic
parts for the safe conduction of media and energy for mobility and industry. They are able to absorb movement and decouple vibrations, and are used in vehicle construction as well as in industry, technical building equipment and aerospace. As a development partner to its customers, Witzenmann works on innovative solutions for a wide range of applications and markets. These include products in the field of new mobility and for hydrogen applications in industry and the energy sector, as well as high-purity parts for microelectronics and semiconductor manufacturing.
To ensure that they function flawlessly, the parts must meet precisely specified requirements for particulate cleanliness.
The advantages of flexible metal hoses in oil, gasoline or cooling circuits are that they are absolutely gas and diffusion-tight, durable and resistant to high temperatures. These are key criteria, especially if they are installed close to manifolds, turbochargers or exhaust systems. “In addition, the hoses usually need to have a very high level of particulate cleanliness,” adds Andrea Krause, expert for technical cleanliness at Witzenmann. This was also the case with an oil pressure line, for which the vehicle manufacturer specified was “no particles larger than 400 µm”. This would not normally be a challenge for the company if it were not for the presence of a 100 mm-long elastomer part integrated into the line. The part has an inner diameter of 8 mm and is sheathed in metal mesh to stabilize the pressure. During assembly, particles are generated that can get into the part. “The line therefore has to be given a final clean,” reports the cleanliness expert. “Achieving the 400 µm specification in a reliable process is quite a challenge, especially as the inside of the parts has to be cleaned. There was no suitable equipment available at the production sites to handle this task, so we had to invest in new cleaning solutions.”
The alternative solutions considered were wet cleaning systems with various process technologies that work in narrow capillaries and the dry quattroClean snow jet technology from acp systems AG. The decisive factor in favour of the dry cleaning solution was that it solved several problems. “Firstly, it saves us having to completely wet, rinse and dry the parts again. Secondly, this cleaning process does not produce any waste water, which would have been a problem at one of the two production sites because we would have been unable to dispose of it for environmental reasons,” explains Andrea Krause.
The snow jet technology uses liquid, recycled carbon dioxide as a cleaning medium, which is guided through a wear-free two-substance ring nozzle. The carbon dioxide expands on exiting the nozzle to form fine CO2 snow, which is then bundled by a separate jacket jet of compressed air and accelerated to supersonic speed. On impacting on the surface to be cleaned, the jet of snow and compressed air develops a combination of thermal, mechanical, solvent and sublimation effects. The interaction of these four mechanisms of action removes particulate contamination right down to the submicrometre range and also filmic
contamination reliably and reproducibly. Since the crystalline carbon dioxide sublimates completely during the process, the cleaned surfaces are dry and free of residues.
The decision was preceded by extensive cleaning tests in the system manufacturer’s technical centre. These demonstrated that the required cleanliness could be achieved in a reliable process. Based on the results, acp then went on to develop the system concept for cleaning the inner surfaces of the parts. “Working with acp was a great pleasure and very straightforward, not least because of their proximity to us,” recalls Andrea Krause. The cleaning system consists of a standard cell containing a linearly movable capillary with adapted nozzle technology.
For the cleaning step, the lower open end of the part is fixed in the process chamber. Then the capillary is inserted into the line at a precisely defined speed where it applies a jet of carbon dioxide and compressed air. The speed and pressure of both media are monitored by sensors. This makes it possible to prove that each component is cleaned with the defined parameters. On the “return path”, the nozzle applies a jet of heated compressed air to counteract condensation on the outside of the part. Detached particles are removed by an extraction unit positioned above the upper end of the part, thus reliably preventing recontamination. “When monitoring the cleaned parts, we discovered that 90% of them even achieved a particulate cleanliness of max. 300 µm. I think the process also has potential for cleaning parts for new mobility. Especially if other types of particles are reliably removed in addition to metallic ones,” concludes the cleanliness expert.
1 1 - 1 4
100,000 m 2 ofexhibitionspace
50,000industrialists
2,500exhibitors
84countries +3,000machinesin operation
Following the success of the previous edition, which closed with nearly 70,000 visitors and more than 2,000 companies participating, the manufacturing industry trade fair MecSpe has announced that its next event will be held from 5th to 7th March 2025 in Bologna (Italy) with a new relevant key topic: Industry 5.0.
In its 23rd edition, MECSPE will focus on the industry’s most relevant and current topics, such as new technologies to support it and talent training. The dawn of the 5.0 era is confirming a key transformation of the Italian manufacturing industry: the continuous technological evolution that enterprises are experiencing poses a significant challenge to maintain competitiveness in a market that is the backbone of the Italian economy.
The Ministry of Enterprise and Made in Italy’s new Transition 5.0 Plan, which will provide incentives for the green and digital transition to supply chain enterprises, is now only around the corner, owing to €6.3 billion in NRRP funding. Without these incentives, most companies would be more reluctant to invest – as many as 6 out of 10, according to the latest MECSPE Observatory. A figure that was recently presented at the inauguration of MECSPE, the benchmark exhibition for the manufacturing industry organised by Senaf, which recently concluded its
22nd edition, held from 6th to 8th March in Bologna (Italy).
In such a crucial period for manufacturing, MECSPE, on the strength of the results achieved, with 66,906 visitors (+12% over 2023) and more than 2,000 companies present, renews the appointment again for next year at BolognaFiere from 5th to 7th March 2025. In an industry that is always changing, the event will provide an opportunity to reflect on recent advancements in 5.0 and government incentives used by enterprises.
MECSPE’s goal is to guide and support companies by accompanying them toward more efficient and innovative solutions for their business, and it has been doing so for more than 20 years by offering a dynamic and diversified platform that connects industry players on the three main thrusts of the fair: innovation, education and sustainability. During the three-day event, there will be educational and interactive moments aimed at illustrating new innovative technologies, conferences
attended by top industry figures, appointments with the most relevant institutions and various networking opportunities, all distributed in 13 exhibition halls over an area of 92,000 m2
Every exhibiting company will benefit from the rich programme of MECSPE, which is dedicated to creating a stage for companies, young people and institutions to converge in the common goal of bringing to life a new, more conscious, responsible and human-centred manufacturing industry.
The innovative and digital soul of the trade fair will be fully expressed in the special areas, with an emphasis on new technology to serve the manufacturing industry, showing how firms may accelerate their transition and increase efficiency. The plazas will be structured with an exhibition/demonstration area and a second dissemination and networking zone, where informative and educational moments will alternate.
“We are very proud of the success of the MECSPE 2024 edition and are facing the planning of the next edition with renewed enthusiasm. In particular, next year, we will devote ample space to the theme of young people and their education: always one of the most relevant focuses for MECSPE. Through dedicated initiatives and events, we will create fertile ground to foster encounters between young people ready to enter the world of work and manufacturing companies, which are always looking
for resources with new and specialised skills. In fact, the primary goal will be to reduce the mismatch between supply and demand, a goal MECSPE is committed to pursuing in each edition by trying to stimulate the liveliness of the market and the curiosity of young specialists,” has stated Maruska Sabato, the project manager of says Maruska Sabato, MECSPE project manager. “.
As per tradition, the next edition will open with the inaugural event, during which data from the new MECSPE Observatory on the manufacturing industry for the third quarter of the year 2024 will be presented.
The new aspects introduced during the previous fair are also returning and evolving, beginning with MECSPE LAB - Innovation Area, the main part of the event that is built each year around a distinctive focus, providing opportunities for meetings and demonstrations with high technological content.
There will be no shortage of the iconic activities of MECSPE, such as the Objective Sustainability Path, the Startup Factory, MECSPE Young&Career and many more initiatives that have served to establish the event as a beacon of industry innovation throughout the years.
For further information: www.mecspe.com
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