ipcm n. 74 - March/April 2022 by ipcm® International Paint&Coating Magazine

The smart journal for surface treatments

ISSN 2280-6083

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Urban reflections City lights are versatile and changeable. Various colors such as gold, orange and later the blue shades of dusk reveal endless shining dots as night approaches. Like glittering gems, countless lights and reflections stand out from the darkness. Be inspired by the surprising effects of Colorstream® and Pyrisma® together with the Living Sparkle® of Xirallic® NXT effect pigments.

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Come visit us at PaintExpo 26 - 29 April 2022 in Karlsruhe.

Grimm Pulverlack GmbH - Hall 3, Booth 3430

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CONTENTS MARCH/APRIL 2022

HOW IT’S COATED

Eurofighter Paint Jobs: Strip-on, Strip-off

07 08 14 28

FOCUS ON TECHNOLOGY

The Cornerstones for Reducing Consumption in Paint shops: Pre-Treatment, Paint Stripping, and Dezincification

FOCUS ON TECHNOLOGY

The Non-Conformist Choice of Sverniciatura Veneta: A Vertical Spray Paint Stripping Plant that Reaches High Temperatures to Optimise Resources and Reduce Environmental Impact

EDITOR’S LETTER

HIGHLIGHT OF THE MONTH

BRAND NEW

ASK JOE POWDER

ZOOM ON EVENTS

INNOVATIONS: PRESENT&FUTURE Lotus Effects by Laser

BRAND NEW

Cost-efficient and Sustainable Solutions

FOCUS ON TECHNOLOGY

Articulated Robots for Flexible, Optimised Coating of Oil Hydraulic Cylinders: The Choice of Bicelli SRL

The “Ask an Expert” Column

PaintExpo 2022 – The Industrial Coating Industry Presents Its Innovations

BRAND NEW

60 72

FOCUS ON TECHNOLOGY MECAL Machinery – An Impressive New Powder Coating Plant for Finishing Aluminium, PVC, and Light AlloysProcessing Machines

BRAND NEW SUCCESS STORIES Rimstock Upgrades Paint Shop

SELF-LEARNING ROBOT 1 OPERATOR REQUIRED EUROPEAN ASSISTANCE

Increase your productivity WITH SELF-LEARNING ROBOT FOR FINISHING

LARGE METAL COMPONENTS NO LIMIT TO COMPONENT DIMENSION'S PRECISION AND REPEATABILITY

PAINTS PLASTIC AND METAL COMPONENTS

on the conveyor system

WOOD DRAWERS, PANELS AND BOXES of different sizes

SELF-GENERATION OF THE PAINTING PATH

AUTOMATICALLY SYNCHRONIZED ROBOT-LINE

YOU ONLY NEEDS TO ADD COMPONENTS/PARTS FOR PAINTING

A SINGLE SUPERVISOR

3D SCANNER VISION

info@Lesta.it www.Lesta.it Lesta srl

Lesta srl

Lesta

Lesta Srl Milan

CONTENTS MARCH/APRIL 2022

FOCUS ON TECHNOLOGY

Barnem Invested in AR Coating for its Plastic Touch Screens: The Future of the Automotive Industry

130

76 80 96

112

FOCUS ON TECHNOLOGY

Increasing the Load Capacity of a Cataphoretic Coating Plant’s Elevator by Around 700 kg with Limited Downtime: The Challenge Won by Verniciatura Padana Foresi and Conveyors Nord

FOCUS ON TECHNOLOGY

144

Welcome in the Rubber Valley: 20 Rotamat Coaters Within a Radius of 10 Kilometres

BRAND NEW

104

FOCUS ON TECHNOLOGY The New Frontier of Small Parts Coating

FOCUS ON TECHNOLOGY Powder Pre-Finishing with Self-Learning Robots: The Key Solution for Finishing Fael LUCE’s Customised Products

120

FOCUS ON TECHNOLOGY Felder: Sustainability, Water Recycling, and Energy Saving in the Production of Woodworking and Metalworking Machinery, with the Atmospheric Pressure Mechanical Compression Evaporation Technology

FOCUS ON TECHNOLOGY Autec Focussed on Decarbonisation and Chose Hybrid Polymerisation Ovens for its New Coating Plant

INNOVATIONS:PRESENT&FUTURE

EcoBell4 Increases System Availability and Capacities

126 136 138 142

SUCCESS STORIES Helping the Customer with Expertise

BRAND NEW HIGHLIGHT OF THE MONTH Chemtec’s Offer in the Post-Pandemic Scenario

BRAND NEW

Your surface protection.

We care.

Surface treatments and nanotechnologies

dn-chemicals.com

PaintExpo 2022 Hall 1 - Booth 1529

CONTENTS MARCH/APRIL 2022

152

Ipcm © RA Energy

HIGHLIGHT OF THE MONTH

164

Alufinish Has Been Building on Trust for Fifty Years

170

148 150 154 156

INNOVATIONS:PRESENT&FUTURE

Energy Consumption of a Paint Shop Reduced by 30%

ART WITHIN SURFACES

176

Laser Technology and Powder Coatings for Outdoor Colourful Sculptures that Resist All Kinds of Weather Conditions

HOW IT’S COATED Black Paints Save Birds

BRAND NEW

162 168

BRAND NEW BRAND NEW The Industry’s Response to the Russia-Ukraine War

172

THE MARKETING CORNER

Digital Marketing Trends 2022: Everything There is to Know

BRAND NEW ART WITHIN SURFACES Artifacts Never Displayed Before and a New Addition to the Historic Westminster Abbey: AkzoNobel Coated 500 Window Frames for the Project

SPECIALIZED TRAINING How Much Does New Tertiary Technical Education Affect Success in Finding a Job?

182

STANDARD&LEGISLATION

184

ZOOM ON EVENTS

Surface Treatments: The Technological Requirements of the Market

eosmarketing.it

Innovation and Technology for Three Generations

orbita.it

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

ne of the terms used in several press releases published in this issue of ipcm® that particularly struck me is “holistic” – which, not surprisingly, is one of the trendiest words these days. But grasping its meaning when associated with the manufacturing industry is not an immediate process. Holistic is the adjective related to the theory of holism. Derived from the Greek word ὅλος, meaning “total”, “whole”, or “everything”, it refers to seeing such “whole” as a unicum and not as the mere sum of its parts. A typical example of a holistic structure is the human body. Holism, therefore, is the tendency to use creativity and development to form wholes that are greater and more valuable than the sum of their parts. Whereas associating the term “holistic” with disciplines such as philosophy, psychology, and medicine is commonplace, it is less so when applied to the industrial sector. Yet, for example, we have been talking for a few years about the importance of having a “holistic approach to Industry 4.0”, in the sense of starting from the digitalisation of processes to improve them and create new, higher value. Of “holism in corporate management”, in the sense of introducing a more human approach to a company’s vision and culture in order to bring back the attention to the importance of working together synergistically and harmoniously rather than competitively. Or of “holistic concepts” for industrial processes of various kinds, specifically coating processes. What is exactly the meaning of what many businesses in both the chemical and mechanical fields of the surface treatment industry are promoting? It means that the coating systems of today must be able to combine all the advantages of each integrated technology in order to offer a different, greater advantage. What needs to be disseminated is a holistic approach to production, which focuses on interconnected systems and pays great attention to manmachine interaction, but also to the basic and advanced training of the next generation of employees, namely those who will handle the future of production. This emphasis on technological aspects, however, should not be excessive and it should not overshadow other important approaches such as offer personalisation, flexibility to respond to peaks and troughs in volumes, and evolution of business and organisational models (see above). These are just some of the ideas and technological concepts that the surface treatment industry will present, after four interminable years of absence, at the PaintExpo 2022 exhibition and that ipcm® has collected in its success stories, reports, in-depth analyses, and press releases dealing with the many companies that want to show their best at the most complete trade fair for industrial coating, the only exhibition always worth visiting in Europe. If you are wondering why you are holding a particularly heavy ipcm® issue in your hand, the answer is easily given: because marketing is also holistic, that is, it focuses on people and not products, using all available channels to reach them. And, whether digital or in print, technical magazines are still the best way to transfer the value of a product to one’s own potential or current customers. Visit us at PaintExpo! Hall 1 - Booth 1442

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

BRAND-NEW

PPG Will Acquire the Powder Coatings Manufacturing Business of Arsonsisi The acquisition of Arsonsisi’s coatings business will allow PPG to produce more sustainable metallic bonding powder coatings.

PG has announced that it has reached an agreement to acquire

“Already recognized as an innovator in powder coatings, PPG has

the powder coatings business line of Arsonsisi. The financial

demonstrated leadership through powder advancements, including

terms of the transaction, that it is expected to be concluded in

edge coverage and fluoroethylene vinyl ether (FEVE) fluoropolymer

the first quarter of 2022 after customary closing conditions, have not

coatings for architectural metals. PPG is the only total solution

been disclosed.

provider who can supply and service powder and all other coatings

Based in Milan (Italy), Arsonsisi is a supplier of specialty powder

technologies. We are pleased that the addition of this business will

coatings for the architectural and industrial sectors and its powder

offer our EMEA customers expanded powder coating options to meet

coatings business line had almost $15 million revenues in 2021. The

increasing demand for these sustainably advantaged coatings,” stated

agreement will allow PPG to acquire the highly automated, small- and

Michael Shukov, the general manager of PPG Industrial Coatings in the

large-batch capable powders manufacturing plant of Arsonsisi in

EMEA region.

Verbania (Italy) and expand its portfolio to include metallic bonding

“We are proud that PPG has chosen to invest in the field of powder

across Europe, Middle East and Africa, which is one of the fastest

coatings by acquiring Arsonsisi’s powder coating division. We have

growing markets for powder coatings often used in specialty finishes

confidence in PPG’s commitment to carry on our legacy, and in

for automotive, appliance and general industrial applications.

its ability to continue to supply our loyal customers with the high-

In addition, the powder coatings developed by Arsonsisi are a highly

performance powder coatings they require,” commented Carlo

sustainable and offer enhanced durability, transfer efficiency and

Junghanns, the Chairman of Arsonsisi S.p.A.

the ability to be reclaimed or reused during application, so they align with PPG’s goal to have 40% of its sales by 2025 from sustainably

For further information:

advantaged products.

www.ppg.com and https://en.arsonsisi.com

The powders manufacturing plant of Arsonsisi in Verbania (Italy).

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

BRAND-NEW

Atotech Launches the Optimal Solution for Long Life Cleaning: UniPrep® System Atotech’s UniPrep® system, a combination of advanced cleaning processes and oil elimination equipment, facilitates high efficiency cleaning and degreasing in standard production.

leaning and degreasing of a metal

environmentally conscious applicators.

all aspects of the cleaning process, including

substrate’s surface are essential for all

UniPrep® cleaners also offer the unique

chemical consumption, maintenance

high-performance paint applications.

advantage of low temperature operation,

requirements and overall operational costs.

To ensure efficient pre-treatment coating

a highly sought-after process trait by

deposition, uniform paint coverage, and

applicators seeking reduced energy

For further information:

adequate corrosion resistance, organic and

costs and improved carbon footprint. By

www.atotech.com

inorganic soils or contaminants must be

utilizing sophisticated surfactant systems in

removed from the surface.

combination with robust builders, UniPrep®

Efficient alternative to conventional degreasing products

cleaners can efficiently function at low to ambient temperature without compromising performance.

For organic soils, conventional alkaline

For superior process versatility, the

cleaners provide the necessary degreasing

UniPrep® cleaner portfolio offers a wide

characteristics to prepare the metal for pre-

range of products developed for spray and/

treatment.

or immersion mode, ideal for pre-paint

However, these cleaners often operate at

applications as well as rack and barrel

elevated temperatures (55 - 80 °C), have a

plating suitable for various industries such as

short solution life and a declining cleaning

automotive, heavy machinery, construction,

efficiency as the organic soils build up.

white goods, or furniture industry.

Additionally, conventional cleaners often

contain phosphorus, boron and alkylphenol

Oil elimination equipment

ethoxylates (APEs), all compounds considered

A natural by-product of cleaning stamped or

substances of concern with increasing

formed metal parts is the introduction of oil

regulation globally, while also being a

into the degreasing solution.

maintenance and wastewater treatment

These soils often limit the solution life of

burden.

conventional cleaners, resulting in frequent

Atotech’s UniPrep cleaners are the ideal

make-ups. With a goal of continuous process

alternative to conventional degreasing

improvement Atotech developed specialized

products. UniPrep processes are capable of

oil elimination equipment, UniPrep® ISOtect,

extended solution life promoting the natural

an easy-to-implement turnkey auxiliary

degradation of organic soils removed and

equipment, to further enhance the efficiency

emulsified during the cleaning process. By

of UniPrep® long life cleaning processes.

achieving this, UniPrep cleaners create

Suitable for the use with all UniPrep® long life

a more efficient and stable process for

cleaning processes but especially effective in

applicators, requiring less frequent cleaner

high oil loading applications, UniPrep® ISOtect

make-ups and reducing wastewater

improves the efficiency of oil degradation.

treatment burden. UniPrep long life

Further enhancing cleaning consistency and

cleaners are formulated without phosphorus,

solution life, it offers applicators a simple-to-

boron, and APEs, providing a solution for

use integrated system that will improve nearly

UniPrep® spray application in white goods manufacturing and UniPrep® ISOtect oil elimination equipment.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

HOW IT’S COATED

Eurofighter Paint Jobs: Strip-on, Strip-off Martin Agüera,

Airbus Defence and Space

martin.aguera@airbus.com

Removing special livery and returning a Eurofighter to active duty in its regular grey paint-scheme can be quite a challenge – especially if you are doing it for the first time. The Airbus Defence and Space team at Eurofighter Kooperation Zelle in Manching made it happen anyway.

pecially painted fighter or transport

In late January 2021, the German Air Force

before,” said Peter Hadwiger, Head of EKZ at

aircraft are a familiar sight in many

(Luftwaffe) delivered Eurofighter 30+68

Airbus Defence and Space. “We had to think

air forces. For special occasions or

(GS0050) from its home base in Neuburg,

carefully about how to proceed and, of course,

dedicated units, such as the famous NATO

Bavaria to Manching for regular maintenance.

to ensure that we could perform all the other

Tigers, some aircraft are given a beautiful

At the time, that particular jet was carrying

activities we do when we overhaul a jet from

design for a certain period of time.

a special paint livery from 2016, when the

scratch to stay within the planned timeframe.”

In most cases today, jets receive a special film

Luftwaffe celebrated its 60 anniversary. As

The pure maintenance work on the one hand

that is comparatively easy to apply and to

part of the maintenance, the jet was also

and the removal of the paint on many parts

remove. In some cases, however, they receive

slated to have its special livery removed and

on the other hand required close coordination

a full-blown paint job.

returned to service in the regular grey paint

between the teams at EKZ.

While beautiful to look at, applying and

scheme.

Communication and coordination between

especially removing the paint is a tremendous

Sounds like a straightforward plan – only it

all of the departments involved turned out to

challenge. It’s a very real challenge that the

wasn’t.

be spot on, even if the overall effort cost “a lot

teams at the Eurofighter Kooperation Zelle, or

“We had a tremendous amount of respect

of nerves,” recalled Stefan Spiegl, Dockchief

EKZ, in Manching faced for the very first time

for that job since scraping the paint off a fully

Maintenance, Repair and Overhaul at Airbus

in 2021.

painted jet wasn’t something we had done

Defence and Space.

Rare sight above Manching: the Eurofighter’s “Frankenstein” version takes off for one of its check flights.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

MRO colleagues needed to give special attention to the parts made out of carbon-fibre material.

“To avoid damage to the parts and to remove the

and Space. What helped the team tremendously

paint effectively, we had to go about the task very

was the experience of several individuals from the

prudently,” Stefan said.

automotive industry.

Furthermore, as this effort represented as first,

“Several of us, myself included, are certified car

alignment with the coordination and planning teams

painters. So we went back to our roots and basically

was of utmost importance. “For MRO, it was the

applied our automotive expertise. Along the way, we

first jet where the entire surface coating had to be

developed new processes and validated every step

sanded down and renewed.”

with our Quality Assurance colleagues. For that, we

As a result, he said, work plans had to be adjusted.

used the smaller parts of the aircraft that were sent

“There was an adjustment to the operational work

to us early on,” said Thomas.

plan that resulted in a considerable additional effort

Compared to the Tornado, special attention must

beyond the standard measure,” added Stefan Kober,

be given to the parts that are often made of carbon

Process Engineer with Airbus Defence and Space in

fibre.

Manching.

“MRO is, after all, manual work. Our experience from

The overall time of the aircraft spent at the EKZ in

having worked on cars, which also use carbon fibre,

2021 was stretched a bit until the so-called “power

was invaluable. It helped us prove that we could

on” as many parts had to be transferred to the

do the job. It showed that no matter how big the

paint shop. The challenge the paint shop faced was

challenge, we can find a solution,” Thomas said.

that there were no written rules or certified work

The smaller parts, which were disassembled from

processes for such a detailed exercise, recalled

the Eurofighter, received their primer within a week

Thomas Biesendorfer, Group Lead Surface for

and were put back on the jet, which was undergoing

Eurofighter and Tornado aircraft at Airbus Defence

maintenance.

HOW IT’S COATED

Eurofighter GS0050 prior to the stripping of the larger parts.

In fact, to save time as much as possible, the

had a great side effect,” said Thomas. It had

an ever greater role in the future. Projects like

aircraft was given special clearance to perform

been the first full paint job since the last series

these give us the opportunity to expand our

the necessary check flights, during which some

production aircraft.

competencies.”

of the parts still had paint applied while the

Thomas and his colleagues took the

In the case of 30+68, the aircraft was handed

primer had already been applied to others.

opportunity to certify an improved water-

back to Taktisches Luftwaffengeschwader

This “Frankenstein” version made for a rare

based paint system that uses significantly less

74 in early December 2021 and immediately

sight in the skies over Manching in the autumn

solvent and is now ready for use in all future

reintegrated into daily operations.

of 2021.

cases.

Despite the complexity of the job, the Airbus

Typically, Airbus’s own test crews perform

“We want and need to become more

teams were satisfied.

several check flights before the aircraft is

sustainable in what we do, and this particular

“Despite the COVID-19 pandemic and many

returned to its operational unit.

job enabled us to put a new system in place

people therefore working from home, this

After the check flights had been successfully

that allows us to become ‘greener’ when

job reflects very good cooperation between

concluded, Thomas said, the jet was handed

painting an aircraft,” said Thomas. Werner

all the departments involved. We often talk

over to the Surface team to strip off the paint

Resch, Head of the Surface Treatment

about ‘We are one’ as a motto in the company.

from the last major parts, such as the wings,

department, added: “I am very proud of the

This job here really showed that it is the case,”

and apply the standard grey paint.

team’s great performance. The topic of paint

concluded Gerry-Norman Doerfl, Aircraft

“The paint stripping on this particular aircraft

stripping from fibre composites will take on

Manager at Airbus Defence and Space.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Protection upgraded

Specialità chimiche per il trattamento delle superfici Lavaggio Industriale

Pretrattamento metalli alla verniciatura

Lavaggio di precisione

Processi di conversione esenti

Sgrassanti interoperazionali

Cromo e Fosfati

Miscele di tensioattivi

Fosfatanti a bassa temperatura

Protezione temporanea

Passivanti per acciaio zincato a caldo Passivazione conduttiva su Alluminio TCP

Galvanica Funzionale

Galvanica Decorativa

Zinco e leghe di zinco

Rame, Nichel e Cromo

Passivanti e Sigillanti

Deposizione su plastica (POP)

Rivestimenti resistenti all'usura

Stagno e leghe di Stagno

Pretrattamento

SurTec Italia Sas di Externa Holding Srl Via Boito, 251 Tel.: +39 059 8579901 41019 Soliera (MO) E-Mail: info-it@surtec.com Italia Web: www.SurTec.com

INNOVATIONS: PRESENT&FUTURE

Lotus Effects by Laser Edited by Fraunhofer-Gesellschaft (München) and Fraunhofer Institute for Material and Beam Technology IWS (Dresden), Germany presse@iws.fraunhofer.de - markus.forytta@iws.fraunhofer.de

Dresden-based start-up Fusion Bionic, a spin-off from the Fraunhofer Institute for Material and Beam Technology IWS, developed a technology which allows to incorporate nano- and microstructures into surfaces in an instant using lasers.

ano- and microstructures can now be incorporated into

versatile than coatings. Product surfaces can be enhanced with all kinds

surfaces in an instant using lasers. The technology is being

of different effects. The lotus effect, for example, uses a microstructure

developed and marketed by the Dresden-based start-up Fusion

to allow any dirt that might stick to the surface to simply wash away the

Bionic, a spin-off from the Fraunhofer Institute for Material and Beam

next time it rains. The fine ripples of shark skin, meanwhile, im-prove the

Technology IWS. The possibilities are virtually endless when it comes

dynamics of air and water on the outside of airplanes and ships, thus

to laser structuring. It has the advantage of being fast and much more

saving fuel.

Modern light interference technologies from Dresden now enable lotus effects to be transferred quickly to technical surfaces such as battery components, implants and even airplanes.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

With nature as their inspiration, many such effects have been developed

by coating or applying a film to the surface into which the microstructures are incorporated. Coatings and films can wear away, however, causing the desired effect to diminish over time. In recent years, researchers at Fraunhofer IWS and Technische Universität Dresden have developed an alternative, marketready method of permanently applying nano- and microstructures to surfaces: Direct Laser Interference Patterning (DLIP). This process incorporates the nano- or microstructure directly into the surface using a laser in order to create biomimetic effects. It is a remarkably quick process, and can currently handle up to one square meter of surface per minute. The new technology is so promising that it led to Fusion Bionic being founded this year as a spin-off from Fraunhofer IWS. Fusion Bionic develops and markets DLIP system solutions for biomimetic surface finishing, but also provides surface functionalization services to its customers.

Fast enough for large surface areas

The founders of Fusion Bionic. From left to right: Sabri Alamri, Laura Kunze, Benjamin Krupop, Tim Kunze.

“For a long time, lasers were much too slow to be used for finishing surfaces with large areas compared to coating or applying films,” says

“This allows us to create virtually any structure imaginable,” says Tim

Managing Director of Fusion Bionic, Dr. Tim Kunze, who founded the

Kunze. “Lotus effects, shark skin, moth eyes and many more.”

company together with three partners. “But with the DLIP process we’ve

Based on a concept developed during the LASER4FUN project, funded by

made the leap to processing large surface areas quickly.” Conventionally,

the European Union, and coordinated by laser expert Prof. Andrés Fabián

people think of a laser as a single fine beam. Using it like a needle to make

Lasagni, Fraunhofer IWS in cooperation with the Technische Universität

a pattern in a surface would be extremely time-consuming. The way the

Dresden and Airbus developed a microstructure that prevents ice from

DLIP process works is different. First of all, it splits a single laser beam

building up on airplane wings during flight. Traditionally, this is achieved

into multiple clusters of beams. To apply a pattern to the surface, these

by piping hot exhaust air from the aircraft engines to the wings. However,

multiple laser beams are superimposed in a controlled way to create what

this wastes energy from the engines. The project found that the energy

is known as an interference pattern. This pattern can be distributed over a

required by an ice protection system decreased by 80 percent when the

wider area, allowing surfaces with large areas to be processed rapidly.

wings also incorporate a DLIP microstructure. “This is an especially good

Let’s briefly explain the principle of interference: light is transmitted in

solution for the electrically powered planes of the future, because those

waves. When two beams of light are superimposed, their wave troughs

engines won’t generate any waste heat,” says Tim Kunze.

and crests can cancel each other out or reinforce each other. Where light

Other projects have worked on processing implants such as

hits the surface, the laser energy re-moves or alters part of the material.

prosthetic hip joints to make their surfaces especially biocompatible or

The dark areas remain unaffected.

antibacterial.

Paint Expo, Karlsruhe, Germany HALL 2 BOOTH 2318 April 26-29, 2022

INNOVATIVE FINISHING TECHNOLOGY FOR DEMANDING SURFACES

Venjakob Maschinenbau – more than 50 years of innovation in surface technology made in Germany SURFACE PRETREATMENT | COATING | DRYING TECHNOLOGY | AUTOMATION | EXHAUST AIR CLEANING

www.venjakob.com anzeige_IPCM_March_2022_214x62.indd 1

11.03.22 07:41

Laser-functionalized glass with decorative Fusion Bionic logo inspired by the morpho butterfly.

Funding through the Fraunhofer AHEAD program

To accelerate the development of innovative surfaces, Fusion Bionic is

The initial push to develop DLIP came around a decade ago from Lasagni

working with the support of its investor, Avantgarde Labs Ventures, on

when he moved from Saarland University to Fraunhofer IWS and shifted

a forecasting platform using artificial intelligence, intended to be used

his focus to technology. At the time, DLIP was more of a basic academic

to develop advanced laser functionalities. In parallel, an AI test bench is

subject, but Lasagni, who is now Professor for Large Area Laser Based

being built at Fraunhofer IWS. This is a multi-sensor laser processing test

Surface Structuring at TU Dresden, saw great potential within this field. He

bench that uses artificial intelligence to quickly predict and create the

formed a highly skilled team at Fraunhofer IWS, developing several optical

optimum surface structure for any problem.

concepts and patents in this field, and it has continued to grow under his

The founding members of Fusion Bionic are Dr. Sabri Alamri, Laura Kunze,

successor Tim Kunze since 2017. Building on Lasagni’s ground-breaking

Dr. Tim Kunze and Benjamin Krupop.

preliminary work, the two of them developed DLIP heads for industrial use that have since been installed by a number of pilot customers around the world. In 2020, it became clear that the commercialization of DLIP technology would need to be raised to a new level. “Our solutions offer a completely new degree of freedom in surface design, with speeds that simply weren’t available before. This means that completely new kinds of products and processes are now possible,” explains Tim Kunze. Fusion Bionic has now been established with the help of the AHEAD program, a spin-off support program of the Fraunhofer-Gesellschaft. “There is a real need for functionalization of surfaces,” says Lasagni in summary. “Every industry has its own challenges, from ice cream sticking to the sides of containers to the question of how to reduce friction. We won’t be out of work any time soon.”

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

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AUTOMATIC FEEDING SYSTEMS FOR PAINTING PLANTS

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

The Cornerstones for Reducing Consumption in Paint shops: Pre-Treatment, Paint Stripping, and Dezincification Monica Fumagalli, ipcm®

Reducing consumption to the benefit of every single aspect of its production system: this was the aim of one of Europe’s leading manufacturers of metal fences, which has improved its coating performance by integrating new pre-treatment chemicals, a paint stripping plant, and a dezincification system supplied by Condoroil Chemical.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

production system is commonly analysed based on four

particular, which has always been one of the most energy-intensive

parameters, i.e. cost, time, quality, and flexibility, linked by a

ones.

common denominator: the need for saving. As already stated

by Keynes, the latter consists of a subtraction of expenditure –

The evolution of pre-treatment

aimed, in the case of manufacturing companies, at cutting costs and

The raw materials, namely steel bars or sheets and wire coils,

consumption in order to invest in technological solutions and improve

is subjected to machining to obtain semi-finished products.

production flows.

Approximately 80% of products reaches the company in the form of

The production system is made up of many components that must be

raw material and is completely handled in-house, ending up packaged

perfectly integrated with each other, with a view not only to optimising

and ready for dispatch.

production, but also to saving money. The implementation of cuttingedge technologies to reduce consumption must be a part of a much wider plan in which each component is crucial in contributing to optimising the production cycle in general and the coating process in

Up until ten years ago, coating did not have the weight it has today in the metal fences industry. The Minerva ultrafiltration plant.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

The Condordemi 900 reverse osmosis filtration unit.

A detail of the reverse osmosis filtration unit.

Until a few years ago, for the surface treatment it performed a cycle of

the formulation of pre-treatment chemicals. Its technicians identified

sandblasting, powder coating, and curing.

the most suitable pre-treatment cycle and, with an eye to optimising

Then, the company also started manufacturing rounds posts and, in

processes, they also integrated an advanced system for recovering and

order to achieve better cleaning of their internal surfaces, it opted for

recycling primary water.

a chemical pre-treatment process in a first tunnel with an iron salt phosphating station, soon replaced by a zinc salt phosphating one.

Pre-treatment chemicals and primary water recovery

Gradually, powder coating has been extended to the company’s

“The process cycle we have developed,” states Livio Salvetti, process

whole galvanised steel production: this resulted in readjusting the

engineer at Condoroil, “includes a degreasing/ deoxidation phase with

chemicals used by adapting them to this type of product, which is

the products Condorite 796 N + Additivo Mix 1312, two rinses, a rinse

already protected by galvanisation but still requires special attention

with demineralised water, and a final nanotechnology passivation

in terms of powder film adhesion. Condoroil Chemical, which had

phase with Condorcoat Al 91. The formulation used for degreasing,

already supplied it with paint stripping equipment, also specialises in

in particular, is a special product that, even at low temperatures and

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

booths

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FOCUS ON TECHNOLOGY

neutral pH values, removes the protective and processing oils and any

for 5 consecutive days, and, in order to optimise water recovery,

oxidation traces formed at the cutting and welding points of posts. The

the company installed an additional Taos 700 reverse osmosis

water that comes into contact with the product used in the degreasing/

concentration unit, which collects and recycles the degreaser-

deoxidation bath is continuously filtered and regenerated in the

deoxidiser drag outs, producing a flow of demineralised water that

Minerva 100 ultrafiltration plant and in the Condordemi 900 reverse

helps replenish the last rinse tank. This has enabled it to create a

osmosis unit, which demineralises the primary water and recirculates it

healthier environment and save the costs of disposing of water and

to the final rinse and passivation stages.”

hazardous substances such as acid and soda.”

The company has been using this system for years now, and its performance level is so excellent that an identical one has installed

A coating process with reduced consumption

in the other production plant, where volumes have quickly become

Up until ten years ago, coating did not have the weight it has today in

very high. Here the pre-treatment plant operates 24 hours a day

the metal fences industry. The application processes and the powders

The Polifluid device for the production of liquid nitrogen.

The static chemical paint stripping system designed and installed by Condoroil Chemical.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

A paint stripping plant and its related dirt separator installed by Condoroil.

used did not receive the attention they do today. As the requirements

now takes 15 seconds. Incidentally, the cyclone has recently been

became more stringent, manufacturers’ needs also became more

modified by replacing the conventional pumps with membranes that

precise and focused. They started looking for higher-performance

reduce the time it takes to send the powder to the recovery unit, so

powders that guarantee long-lasting results for products that have to

that it can be reused immediately.

withstand natural soil corrosion – some customers include a minimum

The Coatmaster powder thickness detector allows perfect

value for salt spray test hours in their specifications – and severe

management of the application process: if the thickness is less than

weather conditions.

or above 50-60 microns, it stops the system. In the range between 50

In this paint shop, standard systems include one coat of powder,

and 60 microns, it self-adjusts the guns by increasing or decreasing the

but it is also offered a two-coat system upon request, exclusively for

flow rate based on the set parameters.

non-galvanised steel, which includes an epoxy-polyester primer and a

The parts are then cured for 25 minutes in the oven, on which the

polyester topcoat with UV resistance technology.

company made a decisive technical modification by building a side

All the company’s three plants are fully automated to apply different

plenum, in order to distribute the recirculated air while maintaining

colours. At the moment, the company does not have the need to

a constant temperature inside the entire system. This has resulted in

apply more tints, and preferred to focus on application efficiency,

lower consumption and a greater reduction in the size of the oven. If

by replacing the injectors with HD pumps, which guarantee a more

necessary, it can be used an infrared oven that has been installed at

efficient powder recovery thus increasing the powder flow from the

the entrance to the curing tunnel for pre-polymerising certain types of

cyclone back into the system, and on the speed of application, which

products.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

SPECIAL ISSUE - PaintExpo

The in-line paint stripping plant.

In order to further reduce product consumption, the company has

“As for the painting line,” adds Salvetti, “the fact that exclusively one

acquired three Polifluid devices. Made by Eurosider (Grosseto, Italy),

type of product was hung translated into less frequent changes,

they use nitrogen as a powder injector in the application phase.

but the hooks were still replaced three times a week due to powder

Polifluid concentrates the nitrogen contained in the compressed air

contamination, which compromised the success of the subsequent

through the principle of selective permeation and uses it as a booster

application. Therefore, we developed an automatic, in-line, ultrasound

fluid in all stages of powder application. Therefore, the use of liquid

paint stripping system that proved to be very effective and capable

nitrogen allows managing the temperature of the fluid and ionise it with

of stripping a hook in 2 minutes. The same type of plant has recently

positive or negative charges. In this way, it can be reduced the humidity

been supplied to the other factory, too, with the addition of a static tank

level and prevent the powder from accumulating on the inside of the

with an automatic water regeneration function, managed by a control

dispensing tube and of the gun, thus avoiding the formation of lumps,

PLC: after paint stripping, this single tank is emptied and rinsed and

which conversely tend to be generated with compressed air. “This has

the resulting recovered water can be returned to the pre-treatment

also brought a considerable advantage in terms of film distension”,

tunnel.”

states the company.

The paint stripping of hooks

The dezincification system During the hot-dip galvanizing phase, a robot has the task of changing

Previously the company used a pyrolytic oven to clean the hooks, but

the bars, on which the pieces are hung to be immersed in the bath

this required a considerable effort in terms of energy consumption,

together with the hooks; these, therefore, undergo the same treatment

operation, and maintenance. As early as fifteen years ago, it replaced it

as the parts at each hot-dip galvanising cycle. This was a critical

with a static chemical paint stripping tank operating in batch mode with

issue because, in order to restore the hooks to a satisfactory level of

a 6-hour cycle.

cleanliness, the zinc had to be removed from their surfaces on a daily

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

EPISTOLIO EPISTOLIO

FOCUS ON TECHNOLOGY

towards the future

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

A detail of the in-line paint stripping plant.

basis by manual operation with a hammer, which posed a huge risk of deforming them. The company knew Condoroil because

Epistolio Srl.

they had supplied it with the paint stripping equipment and, since

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

the two operations of paint stripping and dezincification are quite similar, it turned to them for a solution. After several laboratory tests, Condoroil developed a system consisting of a static tank whose dezincification cycle lasts an average of 4 to 6 hours. The

Publierre_Milano

next step will be the recovery of the removed zinc as well.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

Comparison between galvanised and dezincified hooks.

“This system,” indicates Salvetti, “uses the product Reinox 50 to quickly

chemicals, from the paint film thickness detector that self-adjusts the

remove zinc while preserving iron surfaces and producing a solution

guns to the reduction of oven temperatures and the replacement

that is already prepared for electrolytic recovery of zinc metal, for reuse

of compressed air with liquid nitrogen, every aspect of the coating

in the molten zinc tank.”

process has its weight and it must be analysed in detail, but without

Closing the circle

losing sight of the overall picture. Only in this way is it possible to close the circle and achieve a real benefit in terms of both consumption

“In order to reduce consumption within a production department,”

reduction and process control. During this analysis, it is essential to

concludes the company, “a single device is not enough, but rather

establish a close and fruitful cooperation with one’s own supplier:

several devices must be integrated into a well-designed and developed

with Condoroil Chemical, from the outset we have been optimally

system. In fact, it is the whole system and not the individual technical

supported by its ever-attentive sales and technical team. It is also

measures that make the difference. On the other hand, we are

thanks to this that we can continue to work seamlessly, thanks to

fortunate to be able to concentrate all our efforts on the characteristics

efficient and punctual assistance and knowing that it has done

of one product, so that we can optimise its processing and surface

everything possible to improve not only the quality of its products, but

treatment to the highest level. From hanging hooks to pre-treatment

also its work environment and surrounding area.”

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

BRAND-NEW

HangOn Launches the World Preview of its Ground-breaking Calculation Tool at PaintExpo During PaintExpo 2022, HangOn will showcase a unique online-based calculation tool that calculates the energy consumption as well as the economy in a coating plant.

he calculation tool is a central part of the HangOn’s

be more profitable. In this green plan the calculation tool has a major

sustainability work, which is based on making the coating

part”, explains Petter Törefors, CEO of HangOn.

industry greener.

”It makes understanding what the economy and energy consumption

This is the reason why at PaintExpo the company launches its new

actually looks like in a coating plant. It is complex but we have made

online-based calculation tool which will be available for visitors to

an extensive groundwork to make the calculations correct”.

try. ”During the fair, we will present the HangOn Green Effect, the

The digital calculation tool makes it possible to simulate different

HangOn’s project which is based on making the coating industry

production set-ups, and to calculate energy consumption per painted

greener and at the same time as it opens up great opportunities to

detail and the total savings in a coating plant.

The digital calculation tool developed by HangOn.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

SPECIAL ISSUE - PaintExpo

”We looked at HangOn’s own processes and how we can work sustainably, and found that about 1 percent of the energy is consumed in HangOn’s own production process, including raw material and transport, and 99 percent in the customer’s coating process. Then we understood that the biggest impact HangOn can make on sustainability is to help our customers become more efficient”, says Törefors. The energy consumption in a plant is largely constant, regardless of how much that is being coated. The effect of filling your facility therefore has great potential to save energy and increase profitability – a double effect called “HangOn Green Effect”. ”At the same time as you save energy, you also increase profits. We have previously focused a lot on cost but have not been aware of what energy savings have been made. We now know that energy consumption is constant no matter how much you coat in your facility”, concludes Törefors. HangOn will exhibit in Hall 2, Booth 2110. For further information: www.hangon.com

Petter Törefors, CEO of HangOn.

The FreoCure system will be unveiled at PaintExpo 2022.

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

Cost-efficient and Sustainable Solutions Oliver Zanner, Emil Frei GmbH & Co. KG, Bräunlingen-Döggingen - Germany

o.zanner@freilacke.de

To ensure components coated with various coating technologies would ultimately present a flawless finish, a number of years ago FreiLacke developed its system coating concept. Factors such as sustainability, energy efficiency and climate protection also played an increasingly important role in the development. Within this context, the system coating manufacturer also pressed ahead with powder, liquid and electrodeposition coating and composite solution developments, while simultaneously unveiling wind energy and rail vehicle sector solutions. FreiLacke presents new products within the scope of its system coating concept at PaintExpo 2022 at Hall 1, Stand 1420.

omponents and parts are increasingly manufactured globally

composite solutions, the coating specialist from the Black Forest

before ultimately being locally assembled and coated entirely

is focussing firmly on uniform surfaces irrespective of the diverse

or in part with various different coating systems. As a result,

systems, application processes and facilities involved. Customers

individual workpieces not only need to be perfectly compatible, they

with various production sites, sometimes even located on different

must also present a homogeneous and coherent overall appearance as

continents, are already using the system coatings with great success.

regards colour, gloss and surface structure.

“As a system coating manufacturer, we have the means to perfectly

Meeting these demands while maintaining or improving quality

coordinate the coatings in the course of product development and

standards despite increasingly stricter VOC regulations and faster cycle

production,” explained managing directors Dr. Rainer and Hans-Peter

times requires application solutions.

Frei. “Consequently, not only can we offer our customers all the principal

Coordinated coating technologies

coating technologies, we are also able to harmonise these to optimum effect in terms of coating structure and finish to provide a suitable

This is where FreiLacke system coatings come into their own: with

solution, comply with stipulated framework conditions and ensure cost-

its system coating concept of powder and liquid coatings, EC and

effectiveness and sustainability.”

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Against this backdrop, FreiLacke is unveiling a variety

exert an optical influence on the structure or even

of further system concept developments in all four

cause the powder coating layer to foam. In the

product areas at this year’s PaintExpo.

end, this leads to defective goods or costly extra

EC without labelling requirements for greater sustainability

work”, explains Andreas Hepting, responsible for

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

1925.

Hall 3 | Booth 3334

FreiLacke’s Sales Industry Groups. However, with the new PP5011A product range,

Aspects such as sustainability and VOC reduction

FreiLacke has been able to successfully counter

have long been priorities for the coating

this issue: Even with layer thicknesses that are

manufacturer and are a prime reason for the

far greater than those specified in the technical

continuous range expansion and development

data sheet, the surface will remain uniformly flat;

of new solutions at the Döggingen/Black Forest

that means the surface structure in the range

site. One example is the electrodeposition coating

between 80 and 160 μm is very homogeneous.

‘EcoOne’, a two-component (2K) system free of

This has allowed FreiLacke’s coating specialists to

any solvents and neutralising agents that require

successfully provide automated coating system

labelling. The system is environmentally friendly and

processors and manual coaters with significantly

has no implications for the health of employees.

greater flexibility and scope when it comes to

What is also exceptional about FreiLacke EC systems

coating their components with fine-textured powder

is the fact that they are energy efficient. The required

coatings.

baking temperature of the coating is around 30 °C

In the case of low temperature powder coating (NT),

lower, which equates to a considerable conservation

the baking temperature can be significantly lowered

of energy during the combustion process. An

and heating energy consumption appreciably

outstanding uniform coating film that reliably

reduced. NT coatings also help to considerably

protects the metallic component is nonetheless

shorten the oven throughput time and consequently

achieved. The coating layers are mechanically

increase the conveyor speed. FreiLacke has

resilient and visually flawless.

also successfully pressed ahead with further development in this key area.

Powder coatings: cost-effective, durable and eco-efficient

Powder coatings are similarly a suitable option for

The established Black Forest company’s

simply sprayed into the mould. The highly reactive

environmentally-friendly powder coating range

coating hardens within a few seconds allowing the

has also been consistently developed. The product

SMC/BMC to be immediately placed and pressed.

portfolio encompasses a broadly diversified selection

After pressing, the finished coated component can

for application areas including steel and alloy wheel

be demoulded as usual. The surfaces generated

production, the automotive industry, mechanical and

in the PIMC process feature excellent chemical

apparatus engineering as well as the wind power

and mechanical resistance and are well-suited for

industry and rail vehicle sector. Particularly the

continuous use outdoors. The material is free of

solutions for large and bulky components that forego

solvents, hazardous substances and carcinogenic

the baking process accentuate the cost-efficiency

raw materials. PIMC is fire-retardant in accordance

and sustainability approach.

with EN45545, HL3, R1 and, thanks to its good

Solutions have also been developed to meet the

properties, it can be used for many applications –

challenge of seamlessly distributing the powder

for example kitchen sinks, shower trays, facades,

coating layer thickness on sophisticated geometric

lights, athletic equipment or in vehicle construction.

workpieces, which is often possible only to a limited

A major benefit of this process: by combining

degree in order to adequately cover undercuts or

pressing and coating into a single work step,

cavities, other areas of the component frequently

the laborious subsequent coating (including the

feature denser layer thicknesses. “In the case of

associated parts handling) can be eliminated,

conventional, fine-textured powder coating systems,

as well as the extensive logistics required when

this means that the denser layer thickness will

transporting the components to the internal

coating materials such as SMC/BMC in that they are

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

vollert.de

SPECIAL ISSUE - PaintExpo

FreiLacke EcoOne system - VOC-free anodic EC solution (left photo) and established FreiLacke powder coating systems in use.

coating plant or for external coating. When using the PIMC process, the

Cleverly manufactured composites

components stay in-house until they are completed and can then be

The advantages of glass and carbon fibre reinforced composites

shipped to the customer right away. Another advantage: added value

(GRP/CRP) are apparent: they are light, extremely durable and can

for the operators and lower costs and higher quality for customers.

be moulded into almost any shape. In addition to a diverse range of

Liquid coatings: from filler to top coat

surface coating materials, FreiLacke now also supplies components for manufacturing parts. One example is the new CM powder technology.

FreiLacke liquid coatings provide highly efficient solutions for surfaces

Due to a special two-stage principle, this innovative composite powder

in industrial applications. Whether subject to corrosion, chemicals

stands out against conventional composite material resin systems in

or weather, FreiLacke delivers the optimum protective coating for

that it can be melted on without starting the hardening process.

substrates such as steel, stainless steel, galvanised substrates,

FreiLacke offers numerous coating solutions for composite materials,

aluminium and plastic. The liquid coatings are used at every level of

ranging from colour pastes and fillers to gel coats. These constitute

the coating structure: as a primer or filler, basecoat or top coat as well

durable coloured coatings that are applied directly into the mould and

as in single coat systems. Industry coatings are available in a variety of

provide moulded parts with long-term protection against moisture, UV

finishes and gloss grades for interiors and exteriors.

radiation and impact damage.

Increasingly stricter requirements placed on surface coatings and the

The system coating specialists have also succeeded in significantly

continuous reduction of the VOC content in paints and coatings led

reducing the percentage of styrene in the gel coats as the substance

FreiLacke to develop ultra-high solid systems (UHS). For conventional

is deemed hazardous to health and problematic to the environment.

coatings, completely new coating systems with a solids content of

“Using an alternative monomer, we have manufactured a reduced

up to 80 percent by weight and a VOC value of less than 350 grams

styrene gel coat that delivers even better results than conventional

per litre have been developed and brought to series maturity. They

systems in terms of weather resistance and shelf life,” declared head of

facilitate rapid drying and accelerated production processes. FreiLacke

development Heiko Blattert.

consequently has various single- and double-coat solutions on hand

For components susceptible to increased erosion, such as wind turbine

that offer high resistance for this purpose. Coatings are available in

rotor blades, the coating professionals provide the high-performance

all RAL colours as well as special colours. Easy application – whether

edge protection coating Leading Edge Protection (LEP). New to the

pneumatic, Airmix, Airless or ESTA – and excellent resistance levels

range is a modular production technology that no longer disperses, but

distinguish this system.

only homogenises. Modular coating recipes comprise liquid components

PaintExpo will also see FreiLacke unveil its extremely quick hardening

that can be metered fully automatically and are produced more quickly

liquid coating system FreoCure to industry visitors for the first time.

in order to respond promptly to customer requests.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN

TMC

visit us at

STANDARD

hall 1 - booth 1412

Resistenza alla corrosione Corrosion protection | Korrosionsfestigkeit Durata alle alte temperature Life-time at high | Beständigkeit gegen temperatures | hohen Temperaturen Autolubrifcazione Self lubrification | Selbstschmierung Produttività Productivity | Produktivität

T.M.C. srl

Particolare dei cuscinetti Detail of bearing Ausschnitt der Lager

LESS

Aspetto dopo 200 ore in nebbia salina Surface after 200 hours of salt spray test Aussehen nach 200 Stunden in Salzsprühtest

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

The Non-Conformist Choice of Sverniciatura Veneta: A Vertical Spray Paint Stripping Plant that Reaches High Temperatures to Optimise Resources and Reduce Environmental Impact Gabriele Lazzari, ipcm®

Always open to change, Sverniciatura Veneta has decided to use a technology that is not yet widespread in the sector, namely high-temperature chemical paint stripping with a vertical spray system. The combination of the Fastrip S machine with the products from the Metalstrip range supplied by ALIT Technologies has enabled it to improve the sustainability and efficiency of its process.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

hen it comes to paint stripping, each company relies on a different technology according to the specific needs of the parts it treats. In the case of paint stripping

contractors, however, it is important to implement solutions that allow processing components of all types and in all sizes. The chemical paint stripping industry typically uses the immersion technique, because it enables the whole workpiece to be covered and therefore provides optimum results.

Sverniciatura Veneta S.r.l., a company based in Verona (Italy) that has been treating products of all shapes for over fifteen years, has always been open to technological innovations, offering chemical, thermal, and mechanical paint stripping services. In order to further optimise its services, it also took an interest in high-temperature chemical paint stripping through spray systems. This is why it decided to install a Fastrip S machine, developed in recent years by ALIT Technologies S.r.l. (San Bonifacio, Verona), a company specialising precisely in the supply of complete solutions for chemical paint stripping.

After initial reluctance to embrace such a major technological change, the company worked with ALIT’s engineers to customise a machine that would meet its needs and be able to reach the temperature required by the company (110 °C) in order to achieve high quality results through a faster spray paint stripping process. Sverniciatura Veneta is now capable of providing its customers with uniformly and optimally paint stripped products, while having improved the environmental impact of its processes and reduced resource consumption.

Several technologies for one efficient result Nicola Moratti and Luigi Butti established Sverniciatura Veneta S.r.l. in 2007 to meet the evolving needs of the market and restore workpieces rejected due to coating problems. The history of this business has been marked by continuous investment in new technologies and plant extensions, aimed at meeting all customers’ needs by providing solutions adapted to each specific requirement. Initially dealing with the paint stripping of aluminium profiles and bars, the company focused on chemical immersion operations. Later, at the request of its customers, it decided to implement thermal paint stripping operations, installing a pyrolytic oven to treat hooks and hanging bars. At the same time, Sverniciatura Veneta expanded its immersion plant to be able to treat aluminium profiles with a length of 8 metres and it also installed a shot blasting plant. More recently, the company has added two further chemical immersion paint stripping plants, one of which was supplied by ALIT Technologies to serve customers operating in the small metal parts sector and the other for treating larger components.

Paint stripped parts inside the treatment chamber. Automatic roller shutter closure.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

The control panel of Alit’s paint stripping machine.

“We paint strip a wide variety of items: tools, mailboxes, hanging bars,

with ALIT’s engineers and they provided us with a machine that was

hooks, oil cups, motorbike levers, car brake calipers, high-end rims for

tailor-made for our paint stripping operations on any powder, liquid,

the entire automotive sector, cast iron radiators, and aluminium bars

and cataphoresis-coated components, which can require a temperature

and profiles. Over the years, we have also dealt with plastic and glass,”

of up to 110° C to melt their coatings. A higher operating temperature

explains Luigi Butti.

enables us to achieve high quality results through a faster process,”

Fastrip S, a tailor-made solution for exceeding 110 °C

explains Butti. “In fact, we could say that Fastrip S has even exceeded this requirement, since it operates with cycles that can reach up to

“Having started our business with chemical paint stripping, we have

150 °C and are fully programmable according to the material to be

always been interested in its possible developments. Over the years,

stripped.” ALIT’s machine allows the baskets to be loaded onto a

we have observed and tested a number of spray machines used in

platform inside the treatment chamber, where the nozzles, positioned

other sectors, such as industrial degreasing. However, they reach

on spraying bars, dispense the Metalstrip paint stripping product. The

temperatures that are too low for our operational requirements,

platform underneath the baskets rotates to allow the parts to undergo

generally maximum 80 °C. ALIT’s system, on the other hand, was tailored

uniform treatment. As this is a vertical system, the jet creates a cascade

to our own needs,” adds Butti.

effect, but without aggressive spraying action. The vapours formed due

Fastrip S is a vertical spray system for the chemical paint stripping of

to the high temperature reached inside the chamber, which is perfectly

iron, metal, and light alloy products, which makes it perfectly suitable for

insulated, allow the paint film to be dissolved without any dispersion into

the different products processed by the company. Its compact shape

the work environment.

and its automatically closing rolling shutter have enabled Sverniciatura Veneta to create a special station within its production department, thus

Optimal workpiece arrangement

optimising space in its plant in Albaredo D’Adige (Verona).

When it comes to stripping components with different sizes and shapes,

As it paint strips both small and large items, Sverniciatura Veneta

flexibility in the arrangement of parts within the machine plays a very

needed a customised solution that would allow it to adapt the nozzles’

important role. “One of the many benefits of Fastrip S is the possibility

action to the geometry of the parts being treated. “We worked closely

to arrange the baskets as we see fit and according to individual paint

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

stripping requirements. We even carried out a few tests together

as the duration of the paint stripping process itself, Fastrip S has also

with ALIT’s engineers in order to optimise the final quality of the paint

significantly reduced the need for downstream quality controls. On the

stripping process as much as possible. For example, motorbike rims

other hand, other parts, for example those processed in immersion

are very thin and therefore we can fit more of them in each basket. At

tanks, need to be picked up, checked, and in some cases touched up.

the same time, this machine is also optimal for a whole range of bulkier

“Here, another advantage of Fastrip S comes into play,” says ALIT

parts and semi-finished products. Finally, some bars have holes in them

Technologies CEO, Loris Rossi. “This paint stripping plant is modular,

and they must be arranged so that the paint stripping liquid can pass

so it would be very easy to add an additional spray machine, should

through them and drain effectively, thus avoiding dragging,” notes Butti.

the volume of work increase. If the workload decreases, the second

The film thicknesses treated by Sverniciatura Veneta are variable: they

machine can be simply switched off, thus allowing working with the

are generally around 130 µ, but sometimes the company needs to

first one alone.” “This is another reason why we opted for Fastrip S. As

strip more than 200 µ or less than 80 µ. Of course, the duration of the

a contractor, our production peaks vary over time and we need to be

process also varies depending on the condition of the parts. After the

very flexible, not only in terms of paint stripping processes and materials

initial trials and a settling-in period, this paint stripping contractor has

treated, but also of quantity of batches we are able to handle. In fact, we

been able to find the optimum arrangements inside the baskets and it

have also installed a new scrubber, which is oversized for this individual

has achieved a minimum process time of 20 minutes and a maximum of

machine, but to which we will be able to connect a few others in future,”

around 2 hours.

indicates Butti.

Efficient, ecological, and economical supply

The advantages in terms of optimised costs and times provided by the machine are also added to the ecological and economic benefits offered

Thank to this investment, Sverniciatura Veneta can paint strip different

by the Metalstrip paint stripper, also supplied by ALIT. This company’s

parts in short cycle times, but with a high market value. In fact, as well

research and development division has always focused on providing

Painting for all industries

Bringing your surface to perfection. Dürr offers painting solutions from manual to automatic application, high-quality and easy to integrate. www.verind.it

SPECIAL ISSUE - PaintExpo

From left to right, Michele Merlo and Loris Rossi from ALIT Technologies and Nicola Moratti and Luigi Butti from Sverniciatura Veneta.

products that are both efficient and environmentally sustainable. In

like all technological changes, it presents certain critical issues. Even

this case, the product is made from high quality green raw materials

Sverniciatura Veneta, which has always been attentive to market

that are not yet widely used in the chemical paint stripping industry.

developments and open to change, was initially reticent.

“This even brought an advantageous side-effect: by not using common

“The combination of high temperatures with spray technology is

raw chemicals, the raw materials employed in this formulation have

relatively new. The immersion technique tends to be preferred

undergone a much smaller price increase than other alternatives

because it covers the workpieces completely, whereas in spray paint

currently on the market whose use is more established. By combining

stripping it is necessary to adjust both nozzles and parts to guarantee

Fastrip S and Metalstrip, we have been able to provide Sverniciatura

uniform treatment. This may sometimes require a lot of work and

Veneta with an effective, environmentally friendly, and economical

significant investment. However, ALIT’s engineers explained all the

solution,” states Rossi.

advantages of this technology to us and they were willing to customise

By keeping the pollution level of the paint stripping solution under

the machine according to our needs. In the end, they convinced us

control and by properly filtering the bath, the paint stripper can be

and we decided to buy the Fastrip S system and products from the

reused several times, further reducing the environmental impact of

Metalstrip range.”

the process, the amount of residual paint to be disposed of, and the

Based on these reasons, Sverniciatura Veneta decided to start with

consumption of Metalstrip. “We use several filter presses to treat

only one paint stripping machine. Now, having realised the potential

the process liquid. After removing it from the machine, we let it cool

of this new technology, it is already planning to implement a second

down and, once filtered, we are able to recover it and feed it back

one. “We are very pleased with our investment, because we have been

into the process, while the dense sludge dehydrates in the filters and

able to optimise the management of our workload and the quality of

compacts, thus facilitating its disposal. Recovering the product has

our services while reducing our resource consumption and the impact

allowed us to dramatically further reduce costs,” explains Butti.

our production has on the ecosystem. We have installed an oversized

From reluctance to satisfaction

scrubber precisely because we plan to expand the line with two more paint stripping plants. ALIT was the right choice, because it combines

Still, the technology of chemical spray paint stripping at high

two souls in one company: the mechanical and plant engineering one

temperatures is not widespread within the industry yet, because,

and the chemical one,” says Butti.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Hall 2 Booth 2426

26. - 29. April 2022

Karlsruhe | Germany

GemaConnect® Real-time information from any location With the GemaConnect information platform you get full transparency about the current status as well as the performance indicators of your powder coating lines! The tool offers comprehensive monitoring and analysis options from a single source. Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 F +39 02 48 400 874

gemapowdercoating.com

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

1. Improve first pass transfer efficiency to minimize the creation of overspray which needs to be recycled. This can be accomplished by regular gun maintenance, always ensuring excellent earthing of the parts to be coated, keeping racks clean and using powders with good particle size distribution (minimal fines and coarse particles). 2. Only introducing a low level of reclaim to the virgin powder. Less is always better but it is wise to never exceed a 30% reclaim to virgin powder ratio. Obviously, you need help now because your customer insists on spraying high levels of reclaim. There is hope however the solution is imperfect. It is possible to improve the fluidization and application performance of reclaim powder. The use of a dry-blend additive is worth attempting as a solution to your customer’s application problem. These materials are based on fumed silicas that have been surface treated to make them hydrophobic. The best material to try is based on a silane treated hydrophobic fumed silica. They are supplied as agglomerates of very fine particles of silica typically around 0.2 microns Here we go again with numerous and different questions for our powder

in diameter. Think of them as clusters of grapes. These agglomerates

coating expert, Joe Powder.

can be quite large and therefore will create defects in the finished powder if they have not been adequately de-agglomerated. Hence the

Dear Joe,

mixing process used to disperse the dry-blend additive is important.

I’m a manufacture of powder coatings at Vietnam. We have a

Here are a few guidelines for incorporating a dry-blend additive to the

problem in product as follows:

powder. A good starting point is a concentration of 0.2% by powder

the reclaimed powder is being sprayed on object, but it has

coating weight. Mix the modified powder coating thoroughly. I suggest

very poor transfer efficiency. (I know: the reclaimed powder

a V-blender or something similar to accomplish this. After mixing I

should be added with fresh powder at ratio 70/30 or 60/40, but

recommend sifting the powder through a relatively coarse screen

my customer, he’s spraying the reclaim alone. The particle size

(80 mesh or 175 microns). This can further de-agglomerate the dry-

of fresh powder is 5 microns to 80 microns, D50=28 microns,

blend additive to help minimize the possibility of “seeds” due to large

Percentage of particle size 5-10 microns about 10%). Would

agglomerates.

you suggest for us how to enhance transfer efficiency with

The modified powder will fluidize and transport through the application

reclaimed powder?

system much better than unmodified reclaim powder. I would pay close

I look forward to receiving reply from you soon.

attention to the film thickness of the coated parts. Thicknesses less

Thank you and best regards.

than 50 microns (2.0 mils) may exhibit “seeds” or defects caused by the

Tu Long Nguyen

protrusion of silica agglomerates.

Vietnam

Best of luck Tu Long. If possible, please provide an update of your progress.

Dear Tu Long,

Kind regards,

Thank you for your question. Indeed, this is a challenge. As you know -

Joe Powder

the best solution is to correct the root cause which can be delineated into two issues:

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Joe, I have a few questions for you regarding the powder coating process and defects. I hope you don’t mind taking the time to answer them for me. Here we go: Is there any indication, that static electricity could be causing defects such as fisheyes, cratering or BITS in the powder coating process? Is any static electricity generated in any one of the powder coating systems? What products are commonly used when repairing the types of defects noted above? And, last, but not least, how are powder coating companies ensuring that dust and lint are at a very minimum prior to coating their products? Joe, thank you very much for your time. I really appreciate it. Vicky DeRoven Detroit Hi Vicky, Wow, you have a lot of questions. Let me break them down. Static electricity - yes there is static electricity and from more than one source when dealing with powder coating application. As you probably already know powder coatings are electrostatically charged typically by a corona mechanism near the tip of the business side (outlet) of the spray gun. This works by very high voltage (80,000 to 100,000 volts) being delivered to the electrode. This high voltage ionizes the air creating a field of electrons or negative charge. (Don’t worry the current is very small, typically micro-amps so the process is relatively safe.) The powder is pneumatically conveyed into this electrostatic field, picks up a charge then heads to the nearest ground. The object of the game is to make your parts the closest ground and then the powder deposits on the surface of said part. So, lots of static electricity is generated by the spray system. It’s important to note that static electricity is generated elsewhere in the finishing system. The mere fact that powder particles are being conveyed into fluidizing hoppers, through powder pumps, hoses and spray guns creates static charges. This extraneous generation of charge affects powder deposition and can influence transfer efficiency. Does static electricity cause fisheyes, cratering and “bits”? Probably not. Very characteristic defects are caused by electrostatics however. Excessive charge can build up in a powder coating layer if the powder is applied too thick, too quickly. This phenomenon is known as back ionization. The build-up of charge causes powder particles to microscopically burst away from the substrate. This

Surface Coating Installations Hall 2 Stand 2221

ASK JOE POWDER

causes micro defects that resemble volcanoes. These defects cause a

an abrasive (Scotchbrite™ or 200 grit sandpaper), the surface wiped

rumpled appearance that looks more like localized macro-orange peel

(e.g. acetone), dried and recoated. Alternately you can consider using a

for lack of a better description.

liquid paint-based touch-up if the repair is small and localized. Be careful

Fisheyes are caused by a different mechanism and are more distinct

however as the touch-up may not meet the performance of the original

in their appearance. Fisheyes are created by a significant differential

powder coating finish.

in surface tension between a molten powder film and a contaminant.

Are powder coating companies doing everything to minimize dust

Common contaminants are lubricants and oils. Silicone lubes and

and lint? Do you mean powder applicators or powder coating

penetrating oil (e.g. WD-40) are some of the worst actors. Fisheyes are

manufacturers? High quality coating shops are very clean with isolated

gross defects characterized as deep circular voids in the coating film

application areas that use filtered make-up air. Their processes are

that reach the substrate. Craters are ambiguously defined as defects

carefully monitored and controlled.

similar to fisheyes but smaller in diameter. Craters often do not reach

It’s fairly easy to discern their quality level with a visit and tour of their

the surface of the substrate and typically look like dimples.

finishing operations. As for powder coating manufacturers - there is

As for “bits” I imagine you are referring to unmelted protrusions in

a range of quality. Large producers have prominent quality programs

the finish of the cured powder coating. These are not caused by static

but this doesn’t necessarily mean they clean their equipment well or

electricity. Common sources of “bits” are environmental dirt (oven, spray

that they produce perfectly clean products. If you can tour their facility,

area, unclean application equipment, etc.), unclean substrate or dirty

it will speak volumes on how they manage their manufacturing and

powder coating. They are typically more prominent at thin films (i.e. < 1.5

quality programs. Word of mouth is also a good means to learn about a

mils). If the preponderance of “bits’ decreases with thicker coating films

supplier.

then you can suspect either the powder or a contaminated substrate

I hope this helps you better understand the powder coating process and

surface. If film thickness is not a factor, then the contaminant is probably

how defects occur. Please let me know if you have any more questions.

environmental and is deposited on the powder after it has been applied.

Best regards,

Regarding repair - fisheyes, craters and “bits” need to be buffed with

Joe Powder

Fisheye craters caused by a gross contaminate, likely oil or lubricants.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Cratering from oil or lubricants and “bits” from environmental contamination.

PAINTING LINES A N D

M A N U FA C T U R I N G

we are on Linked

D E S I G N

painting lines design and manufacturing painting lines modernisation audit of painting lines painting scraps reduction microscopic analysis of defects on painted surface problem- solving for painting defects

QUALITY PAINTING DEVELOPMENT SP. Z O.O. ul. Azotowa 15b, 41-500 Chorzów, POLAND www.qpd-poland.com

Get you r ticket now!

World´s Leading Trade Fair for Industrial Coating Technology 26 – 29 April 2022 Exhibition Centre Karlsruhe, Germany

www.paintexpo.com In cooperation with:

AN EVENT BY LEIPZIGER MESSE

ZOOM ON EVENTS

PaintExpo 2022 – The Industrial Coating Industry Presents Its Innovations PaintExpo, the World’s Leading Trade Fair for Industrial Coating Technology will take place from 26-29 April 2022 in Karlsruhe (Germany).

he eighth edition of PaintExpo will take place from 26–29 April

by the state of Baden-Württemberg, which expressly permit trade fairs

2022 in Karlsruhe and offer visitors countless premiers showing

again, a framework is now in place for a safe and successful PaintExpo.

for the first time anywhere in the world, in Germany or at a trade

Exhibitors will be presenting their very best services and products.

fair. Anyone working in contract coating, for in-house coating companies

Visitors can look forward to four days of high-quality contacts and

or otherwise involved in the coating technology industry can look

inspiring innovations.”

forward to experiencing a wide variety of ground-breaking innovations

New products on display at PaintExpo cover the entire range of

live for the first time.

industrial coatings. From wet coatings and powder coatings to coil

All this serves to confirm the position of the world’s leading trade fair

coatings, this unique global showcase for industrial coating technology

for industrial coating technology as the most significant platform for the

encompasses coating solutions for all industries, applications and

industry. With more than 400 exhibitors from 27 countries, it represents

materials. From surface preparation to coatings and spraying production

the entire industrial coating technology and surface coating supply

lines right through to final quality control, visitors to Karlsruhe will

chain.

experience both evolution and revolution in processing and materials.

“PaintExpo exhibitors are coming to the world’s leading trade fair for who of the industry will be presenting their innovative strength and

Directory of Exhibitors and Products Available and Ticket Shop Open Online Now

highlighting trends in improving quality, efficiency, and flexibility. Visitors

Many more exciting innovations from global industry leaders,

will be shown practical solutions for the sustainability and digitalisation

established medium-sized companies, and young start-ups can be

of their production processes. Everything is coming together beautifully

found in the directory of exhibitors and products on the PaintExpo

for a tremendous on-site event in Karlsruhe with personal trade

website. Visitors can now order tickets for the trade fair via the online

discussions, concrete project planning and investments in the future,”

ticket shop.

industrial coating technology with an explosion of innovations. The who’s

says a pleased Markus Geisenberger, Managing Director of Leipziger Messe. He continues: “Thanks to the latest COVID-19 regulations issued

For further information: www.paintexpo.de

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

BRAND-NEW

J. Wagner GmbH Will Exhibit at PaintExpo Wagner will showcase its powder and liquid coating solutions at the international trade fair PaintExpo. © J. Wagner GmbH

High-speed rotation atomizer TOPFINISH RobotBell 1 ECH with external charge; Dynamic 3D coating; Information & management platform COATIFY.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

SPECIAL ISSUE - PaintExpo

Custom-built painting installations

. Wagner GmbH has announced that it will take part in PaintExpo,

Macchine e impianti realizzati su misura

the international trade fair dedicated to the paints and coatings industry that will take place from 26th to 29th April 2022 in

Karlsruhe (Germany). The company will showcase its products

Shot blasting booths

portfolio covering a wide range of applications, from individual

Cabine di sabbiatura

components to fully automated coating systems. Wagner will focus on presenting the IPS Coating Center, a complete solution to achieve consistently high coating results over a long period of time, and the Dynamic 3D coating, that enables precise gun movement control for highest automatic area coverage with minimum powder consumption. Visitors will also be able to

Washing tunnels

experience the liquid coating solutions offered by Wagner, such

Tunnel di lavaggio

as manual and automatic guns for airless, AirCoat and airspray applications and high-speed rotation atomizers for automated coating with robots and reciprocators. In addition, the business will display also its COATIFY platform, a solution that allows to reach reliable productivity monitoring in order to optimise costs and quality, as the user has important performance data at a glance anytime and anywhere. Finally, Wagner Academy will provide expert knowledge on all aspects of the latest application technology.

Liquid painting installations

Impianti di verniciatura a liquido

WALTHER Spritz- und Lackiersysteme GmbH will also be a co-exhibitor. The member of the WAGNER Group will offer its solutions for handling and application, from complex material conveying systems to high-performance precision spray guns. J. Wagner GmbH will be in hall 3 at booth 3330. Powder painting booths

For further information: www.wagner-group.com

Curing ovens

Forni di cottura

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu Eurotherm Oberflächentechnik GmbH T +49-7571-92795-10 | M contact@eurotherm.eu Eurotherm France S.A.S. T +33 (0) 4 90 55 20 75 | M france@eurotherm.eu

IPS Coating Center.

www.eurotherm.eu

Visit us at Stand 3510 Hall 3

26 - 29 April | Messe Karlsruhe, Germany

Made with passion in Italy

Cabine di verniciatura a polvere

BRAND-NEW

SPECIAL ISSUE - PaintExpo

OMIA to attend PaintExpo 2022 OMIA will attend PaintExpo, the international trade fair dedicated to the paint and coating industry, which will take place from 26th to 29th April 2022 in Karlsruhe (Germany).

t the fair, OMIA will showcase its expertise in providing the

In addition to manufacturing in-house all its products, OMIA also provides

best solution for both small paint shops and large industrial

customer support and maintenance services, which include repairs,

installations. The product range offered by OMIA includes

maintenance, spare parts, consulting, filters for all type of booths and

standard applications – spraying booths for liquid and powder coatings,

much more. The fair will also be the perfect occasion to celebrate the

ovens, shot blasting booths, spraying tunnels for surface preparation

company’s 75th anniversary.

using chemical processes, washing and degreasing booths, penetrant

OMIA will exhibit at PaintExpo in Hall 2, booth 2115.

inspection installations – and special, tailor-made coating booths for various industries, i.e., aerospace, railway, marine, metallurgy, agriculture, wood and plastics.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

For further information: www.omia.fr/en/

BRAND-NEW

SPECIAL ISSUE - PaintExpo

Rostirolla Develops an Innovative Silicone Interlocking Component In order to provide a highly flexible solution, Rostirolla has developed a high-rigidity silicone interlocking component that allows to assemble a modular frame in a few simple steps.

ostirolla – a company specializing in the production of

system can also be seen at production level, as we are able to fulfil orders

accessories for industrial coating operations – has developed a

within the day, ensuring an even more timely delivery and optimizing the

simple and effective silicone component that allows to assemble

design and sampling phases”.

a hanging frame in a few seconds, enabling faster and more flexible

The development of Rostirolla’s silicone interlocking component not only

coating operations. The silicone interlocking component is designed to

integrates the GNW system but is also part of the company’s broader goal

be used in combination with the BL bar of the GNW hanging system,

of industrializing key components, compatible with each other that – once

characterized by a diamond-shaped slot that makes the insertion of

assembled – allow a great variety of combinations of use and a faster

metal hooks extremely practical and fast. In fact, until now the BL bar

hanging process.

could not be used alone and needed to be welded or adapted in order

Rostirolla will exhibit at PaintExpo in hall 2 booth 2520.

to be mounted on the frame. Thanks to the new silicone component, the BL bar can now be used in combination with the frames already on

For further information: www.rostirolla.it

the market. Moreover, the coupling between the bar and the silicone component can be performed manually, directly by the user, without the need for welding. “Until now, we have always designed and manufactured fixed or modular metal frames,” explains Simone Rostirolla, who is at the helm of the company together with his brother Pierluigi. “However, metal requires more or less long production times and, once it leaves the factory, it is no longer possible to change its shape. All this prompted us to look for an alternative solution to traditional metal frames and we have thus come to develop a high-rigidity silicone interlocking system that allows to assemble a modular frame in just a few steps”. “The advantage is obvious: the components don’t have to be welded; therefore, coating operators can assemble the hanging frame according to their needs, simply by keeping the BL bars and silicone components they need in stock”, continues Simone Rostirolla. “The benefits of this

Temperature Profiling Systems Optic System:

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Comprehensive Video and Temperature

ATEX System

New Software

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Certified for ATEX classified Zone

ix Phoeonr ! Fact graphical cure

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see us at :

PaintExpo Karlsruhe Hall 2 Booth 2339 www.phoenixtm.com info@phoenixtm.com

MECAL Machinery’s Geos MDT system for machining profiles.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

MECAL Machinery – An Impressive New Powder Coating Plant for Finishing Aluminium, PVC, and Light Alloys-Processing Machines Alessia Venturi, ipcm®

What and how many parameters need to be analysed when assessing an investment in a new production plant? They are certainly numerous, from the latest technologies available for a certain production stage to the expertise of one’s own operators, up to production requirements in terms of volume, time-tomarket, and efficiency. In this respect, when planning a major investment for a strategic phase, it would be advisable to devise it with a view to meeting all the needs that may emerge in the long term, not just in the present or short-term future. This is the principle that guided MECAL Machinery in its decision to invest in one of Europe’s most impressive coating lines, designed and built by a group of Italian suppliers that included Silvi Srl (Peregallo di Lesmo, Monza e Brianza), Futura Convogliatori Aerei Srl (Robecco Pavese, Pavia), and Siver Srl (Corciano, Perugia).

3,000 machines sold, more than 30 international patents,

company that has contributed to Italy’s industrial history. Founded in

50,000 m of production facilities, 180 employees, and over

1978 by Ennio Cavezzale, its current President, and Rosella Meschini –

7,500 customers worldwide: in short, these are the figures

a close couple both in work and in life – MECAL Machinery specialises

behind the success of MECAL Machinery Srl (Frascarolo, Pavia), a

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

in the production of plants and systems for processing aluminium,

FOCUS ON TECHNOLOGY

The loading station with the elevator installed by Futura Convogliatori Aerei Srl.

PVC, and light alloys. It can provide both standard and highly

large companies often require complex machining systems to be

customised solutions for a wide range of sectors, including automotive,

integrated with each other; medium and small-sized companies, on the

lighting, furniture, architectural façades, doors and windows, and

other hand, often need customised stand-alone machines,” explains

shipbuilding.

Ennio Cavezzale. “MECAL Machinery’s production chain provides

Indeed, one of its many strengths lies in the broad diversification and

customers with an articulated range of models, all characterised by a

customisation of its offer, which consists of a wide range of processing

high level of technology and innovation and, at the same time, by such

machines and systems to meet the demands and needs of both large

an ease and practicality of use that makes them simple and functional.

and small or medium-sized businesses. Flexibility towards customer

Our products are designed, developed, manufactured, and set up

needs, use of innovative technologies, rapid response to market

on a turnkey basis and ready for immediate use, be they standard or

changes, complete solutions for complex production systems, highly

customised systems.”

qualified after-sales staff, effective local presence, and proximity to

The pillars of MECAL’s growth and positioning as a leader in its sector

customers through its network of dealers and distributors are the keys

are its ability to design and develop its entire range of solutions in-

to the international success of MECAL, which exports up to 80% of its

house, a production cycle that is also carried out completely in-house

production.

and autonomously, and a focus on technological innovation both in

MECAL Machinery is present all over the world through joint ventures,

its production facility and in its end products. Such propensity for

distribution agreements, and direct sale offices that promote and

innovation, always aimed at meeting its own future requirements and

optimise its level of service to end customers. “Industrial groups and

not only its present needs, led MECAL to install a new, impressive

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

General view of the plant, with the pre-treatment and drying area to the left and the powder application station to the right.

powder coating plant. A Futura Convogliatori Aerei two-rail conveyor

materials to end products. Performing the entire production cycle

with a load capacity of 4,000 kg; a pre-treatment tunnel, ovens, and

in-house also ensures that products can be constantly updated, even

accessory equipment designed by Silvi Srl with particular attention

those intended for major applications. All the elements, functions, and

to energy efficiency, heat reuse, safety, and comfort of the working

applications of each individual machine are the exclusive responsibility

environment; and Siver powder application booths with Nordson

of MECAL Machinery and they belong to its technical heritage and

Encore® HD dense phase powder spraying technology for the highest

know-how. In recent years, its entire production department has been

possible coating consistency and transfer efficiency: all this makes

completely renovated and further upgraded in every area of activity. In

MECAL’s plant one of the largest, most efficient, and advanced powder

fact, another element that has always distinguished MECAL Machinery

coating systems for sheet metal installed in Italy in the last five years.

is its fleet of machines and its extremely flexible and dynamic

Vertically integrating production to offer the best quality and service levels

production system, guaranteeing quality solutions with proven technological innovations that stand out among those available on the world market. As a key step in its production cycle, finishing is a crucial

MECAL Machinery implements its entire production process exclusively

element of this strategy.

and completely in-house, without relying on external suppliers. This

“At MECAL, the whole process is perfectly integrated: iron goes in and

clearly differentiates it from any other operator in the sector, as it

finished machines come out, thanks to our carpentry, welding, sheet

is the only company in Italy handing the whole workflow from raw

metal cutting and/or bending, turning, milling, and finally coating and

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The 56-metre long, 4-cell, 5-stage pre-treatment tunnel designed by Silvi Srl.

mechanical and electrical assembly operations,”

already had a smaller powder application system

says Luca Meschini, manager at MECAL. “As for the

but, as demand continued to increase, we set

latter, we have an in-house department devoted to

ourselves the goal of doubling production in the

the wiring and construction of switchboards. These

medium term. As a result, a new coating plant

are followed by testing and customer approval.

was no longer enough: a line of sufficient size and

We produce 75 machine types with an infinite

capacity was needed to meet current and future

number of variants, from small systems to 5-axis

demand, up to double the current one. Our founder,

CNC centres. We are one of the few companies that

Ennio Cavezzale, is known for having a futuristic

implement a fully integrated process: everything that

vision for our company, for never investing “only

MECAL produces is also conceived, designed, and

in what is needed at a particular moment” but

industrialised by MECAL itself, which owns all the

for orienting any choice towards the future. Over

product know-how.”

the years, MECAL has expanded its production

COMPLETE SOLUTIONS for

HANGING and

MASKING PaintExpo 2022 Hall 2 - Booth 2520

department four times, with a view to future “The idea of investing in a new powder coating

developments; with the last one, completed in June

plant came about because of a sharp increase

2021, our production area has reached its current

in production volumes,” indicates Meschini. “We

width of 50,000 m2, so much so that it is now one of

www.rostirolla.it

SPECIAL ISSUE - PaintExpo

the largest factories in Europe, housing the most advanced production technologies and placing MECAL at the top of its sector. With its 56 metre-long pre-treatment tunnel and 1,100 metre-long two-rail conveyor, our new coating line is also one of the largest in Europe.”

Plant features The new plant designed by Silvi and Futura Conveyors consist of a two-rail overhead conveyor with a 4,000 kg capacity and 13.5 metre load bars, a 5-stage pre-treatment tunnel, 2 Siver automatic coating booths working simultaneously and featuring Nordson’s dense phase application technology, energy-efficient drying and curing ovens, a demineralisation system, a blow-off station, and management © ipcm

software 4.0. The two-rail overhead conveyor designed

The final segment of the pre-treatment tunnel with the demineralisation station.

by Futura operates in a step-by-step mode with a 12′ pitch or in a continuous flow mode with a speed of 1.5 m/minute. Two guided elevators help loading and unloading parts. The bars’ pitch is 2,000 mm at the storage buffers and 14,500 mm on the line (variable). The conveyor accommodates 25 bars with a size of 1,700 mm x 13,500 mm x 2,200 m in height. The production rate is 5 bars/hour. The capacity of each individual bar is 4,000 kg. There are 3 storage buffers, located in front of the pre-treatment tunnel, before the coating booths, and before the curing oven. A special design feature of this conveyor is that it also includes 1 load bar, precisely identified by the management software package, which was designed to carry a maximum load of 5,000 kg, in order to meet any higher load requirements. The pre-treatment tunnel designed by Silvi includes 4 cells, one of which performs 2 phases for a total of 5 cleaning stages. © ipcm

General view of the plant, with the storage buffer housing the parts after curing. A segment of the long pre-treatment tunnel can be seen to the left, with the workpieces moving towards the powder application area.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Parts up to 13.5 metres long can be subjected to its 5-stage cycle, including degreasing, rinsing with mains water,

ECO-CONSCIOUS GENERAL INDUSTRIAL COATINGS Whatever you paint, we have technologies that help to meet your sustainability goals

To learn how we can work together to achieve your sustainability goals, to discuss our broad range of industrial Liquid, Powder and E-Coat coatings solutions, visit us at Paint Expo April 26 to April 29, 2022 in Karlsruhe, Germany

Hall 2, Stand no. 2140 industrial.sherwin.eu Contact: gi.emeai.marketing@sherwin.com

SPECIAL ISSUE - PaintExpo

The application area with the two Silver Booth automatic booths supplied by Siver Srl working simultaneously.

rinsing with recirculated demineralised water. At the exit of the

The powder application system: the winning choice of the dense phase technology

pre-treatment tunnel, there is a very powerful blow-off system to

“MECAL Machinery mainly applies 4 colours to its products, which

remove any water residue trapped in the profiles. It is followed by

means that only a few colour changes are required daily in our

a traditional indirect hot air drying oven, featuring automatic doors

booths,” explains Luca Meschini from MECAL. “However, we decided

for minimum heat loss, which dries the parts in about 20 minutes. At

to install two booths, respectively for light and dark colours, so

this point in the finishing cycle, the plant layout includes an area for

that they could work simultaneously and further increase the line’s

natural cooling of parts, which then reach the storage buffer in front

productivity.”

of the two automatic powder coating booths.

The entire application system was designed by Nordson and Siver,

Another particular design feature of MECAL’s coating plant is the

the exclusive dealer of Nordson systems in Italy, which installed 2

absence of gas or open flame sources within the factory. “All heat

booths of its own design from the Silver Booth series, each equipped

generators and natural gas burners are installed in covered and

with 16 Nordson Encore® HD automatic guns. The booths are fully

insulated outdoor areas, thus maximising safety as there are no

automated with a shape detection and reading system and a Siver-

gas sources inside the building where the coating line is located.

designed Dual powder feeding unit. The external touch-up platforms

This was a design choice shared by Silvi and MECAL to ensure

significantly improve the working conditions of operators. In addition

safety, operational comfort, and absence of noise in the working

to being particularly well lit, Silver’s booths are characterised by a

environment,” emphasises Daniele Fumagalli from Silvi Srl.

very large working surface and by the absence of powder around the

rinsing with demineralised water, nanotechnology passivation, and

operator.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

POWDER COATING

Spray Systems

Maximize the automatic coverage and save powder with Nordson Dynamic Contouring Movers The booths include a pre-finishing platform, an automatic application area with 16 guns, and a post-retouching platform.

“The powder management unit installed at MECAL’s factory is of the newly-designed Top Color Change Dual type, which revolutionises colour change operations by reducing the whole process to just a few seconds. As there are 2 powder tanks, while one is working the other can be prepared for the next colour. An advanced pneumatic exchanger switches from one tank to another in 20 seconds, including guns blow-off,” explains Gabriele Brambilla from Siver. “This allows for a burdensome operation, which requires time and attention from the operators, to be completed with a very limited downtime. This powder feed centre configured in this way only works with Nordson’s HDLV technology. The booths’ control panel is the Nordson iControl system, an industrial PLC managing powder delivery: it acquires relevant data and adjusts the guns’ speeds depending on the incoming workpiece.” The powder application area is completed by a

n Increase automatic powder coating coverage of complex products n Reduce powder consumption by improving the applied coating uniformity n No programming required – fully automatic gun positioning with scanners n Stay in control of all system functions and data collection with our advanced PowderPilot ® HD system controller Get in contact with Nordson today for more information or explore the unique features of our powder coating systems online at www.nordsoncoating.com/showroom

manual booth devoted to more extensive touch-up operations and to the finishing of special profiles or display pieces.

ics.eu@nordson.com www.nordson.com/hdlv

SPECIAL ISSUE - PaintExpo

Siver’s Top Color Change Dual powder feeding centre with Nordson HDLV technology. The Nordson HDLV pump technology chosen for the 16 spray guns (right photo).

A satisfied customer ready for future challenges

the production process.” Ennio Cavezzale explains the high standards

“Although the line has only been in operation for a month and a half,

the production has to meet. “The powder is transported by the

we are very pleased with it,” concludes Ennio Cavezzale.

durable and long-lasting HDLV® Encore HD pumps. Their advantage is

“We have been working for many years with both Futura and Silvi,

the uniform and controllable flow rate. This ensures optimum process

which had also designed our old powder application plant. We chose

control throughout the coating process. The pumps supply powder

Futura because we believe it is the leading manufacturer of conveyors

from the tanks to the guns, transport the overspray collected in the

on the market, whereas we have always worked well with Silvi in terms

booth to reprocessing, and from there back to recovery. The design,

of both design and technical assistance, which is reliable, punctual,

installation, and start-up of this line took two years: the pandemic

and fast. Finally, we turned to Siver-Nordson because we think that

delayed the work by a few months and the system is still in the

the dense phase application technology is the most innovative

ramp-up phase, but I feel that I could not have made a better choice.

available today. Also quality has always been a high priority for us.

With this plant, MECAL Machinery is truly ready to face the future

Therefore, we highly focus on the quality control of the products in

challenges of the machine tool market.”

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

CHEMICALS MAKING SOLUTIONS

• TRATTAMENTO ACQUE WATER TREATMENTS

• SVERNICIANTI PAINT STRIPPERS

• PREVERNICIATURA E NANOTECNOLOGIE COATING PRETRATMENT AND NANOTHECHNOLOGIES

• SGRASANTI INDUSTRIALI DEGREASERS

NOXORSOKEM.IT

BRAND-NEW

SPECIAL ISSUE - PaintExpo

PhoenixTM will Showcase its New ATEX-, Optical Systems and More at PaintExpo After the forced stop caused by the pandemic, PhoenixTM GmbH will return to submit its new technologies to the coating market at PaintExpo 2022.

efore and during the pandemic period which caused the

are difficult to access (cavities, bends, etc.).

cancellation of most exhibitions, PhoenixTM GmbH developed and

These innovations were already described by the technical and trade

launched various new products. In the coating sector, these were:

media, but there have unfortunately been only few opportunities to

• explosion-proof ATEX system “Epsilon-x” for hazardous areas

present them live due to the cancellation of the PaintExpo in 2020.

• optical system “TS64” for easy inspection of the oven interior

PaintExpo 2022 will give all visitors this opportunity.

• the revised FIS04 software with the “Phoenix Factor” as a new feature

PhoenixTM GmbH will exhibit in Hall 2, booth 2339.

which makes the evaluation of the profile recording in coating processes even easier and more convenient for the user. • new thermocouple attachments which are able to measure in areas that

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

For further information: www.phoenixtm.de

BRAND-NEW

SPECIAL ISSUE - PaintExpo

H2O GmbH Increases Long-term Effectiveness and Better Rinse Water Results with Smart Services H2O GmbH offers an efficient and sustainable and excellent quality/price ratio solution for stable cleanliness.

leaner, better, cheaper - in painting technology,

is ideally suited for reuse in the process and thus

the requirements for stable cleanliness and

reduces disposal costs enormously.

the cost pressure are continuously increasing.

To ensure that wastewater treatment operates at a

H2O GmbH (Steinen in Baden, Germany) offers high-

high level in the long term, H2O GmbH has developed

quality rinsing water treatment that saves costs. This

smart functions to be added to the Vacutouch

efficient technology will be explained by the Leaders in

machine control system and innovative analyses to

Zero Liquid Discharge at PaintExpo 2022.

increase efficiency with its Smart Services innovations.

The quality of the rinse water treated with VACUDEST

They provide users high system availability through an

sets high standards thanks to patented innovations.

optimised system and fewer maintenance failures.

For example, the Clearcat technology produces

H2O GmbH will exhibit in Hall 1, booth 1501.

crystal-clear, oil-free distillate that enables excellent cleaning results in surface technology processes. It

For further information: www.h2o-de.com

BRAND-NEW

SPECIAL ISSUE - PaintExpo

Surface Protection Combined - Dörken and Sidasa at Paint Expo 2022 Dörken will showcase its own coating solutions at this year’s PaintExpo in a joint booth with Sidasa Engineering.

rom April 26th to 29th the perfect combination of plant engineering

Sidasa. From the conception to the commissioning of a coating system,

and chemistry will come into play at the joint booth of Sidasa

we coordinate closely and carry out audits, sampling and quality controls.

Engineering and Dörken at PaintExpo in Karlsruhe. In this joint

By combining the know-how of both companies, the customer ultimately

booth the visitors can find out about the latest developments in surface

gets a perfect solution and thus real added value. We would like to thank

protection solutions.

Sidasa for the opportunity to show our coating systems – such as the zinc

Project support from conception to implementation

flake technology – at the booth and look forward to a successful trade fair with many interesting conversations.”

Sidasa Engineering and Dörken has been working closely on a wide variety

The PaintExpo’s visitors can find out in detail exactly what such

of projects for years.

cooperation looks like in practice.

Klaus Gradtke, Key Account Manager at Dörken, explains: “In order to be

Dörken and Sidasa will exhibit in Hall 2, joint booth 2540.

able to offer our customers a solution that is precisely tailored to their coating requirements, a suitable system and application technology is of

For further information:

course also required. Here we are always happy to use the expertise from

www.doerken.com and www.sidasa.es

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

BRAND-NEW

SPECIAL ISSUE - PaintExpo

Venjakob - Innovative Spirit Meets Technology at PaintExpo 2022 Venjakob Maschinenbau will present a wide range of holistic concepts for efficient coating at this year’s PaintExpo.

enjakob offers the entire range of surface treatment solutions,

with higher-level system control and, if required, integration of third-party

from pre-treatment and coating plants to drying systems combined

systems.

with the latest automation technology and completed by exhaust

At this year’s PaintExpo, Venjakob will not showcase a system solution,

air purification systems.

but rather its competence in meeting the most diverse requirements for

With almost 60 years of cross-industry expertise, inspired by global

individual and extremely flexible solutions. Visitors will be encouraged to

industrial customers and the demand for resource and energy

gain insights into plant concepts that have already been implemented,

savings, the company continuously rethinks and revises all processes,

and rethink their coating processes, integrating them with the new

and customizes them to different customer and global sustainability

different solutions offered by Venjakob.

requirements. Venjakob, as a general contractor, combines a wide variety of application

Venjakob Maschinenbau will exhibit at Hall 2, Booth 2318.

systems, drying techniques and automation solutions for a wide range of applications: from individual machines to fully automated coating lines

For further information: www.venjakob.com

WE ARE LOOKING FORWARD TO YOUR VISIT AT THE PAINTEXPO 2022 Free Tickets: www.kabe-farben.ch/paintexpo

Trade Fair Karlsruhe April 26-29, 2022 Hall 2 · Booth 2410

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

Articulated Robots for Flexible, Optimised Coating of Oil Hydraulic Cylinders: The Choice of Bicelli Srl Gabriele Lazzari, ipcm®

In order to paint oil hydraulic cylinders with different sizes, shapes, and characteristics, Bicelli Srl revamped its coating plant by adding two Lesta robots with a self-learning module. The company is now able to optimise its resources, thanks to speeded up production times and a reduced amount of dispersed paint, and to give its components a uniform, high-quality coating.

he market for oil hydraulic cylinders is growing rapidly and

In order to meet this challenge, it turned to Lesta Srl, which supplied

calling for ever-greater attention to corrosion resistance, which

it with two Lesta LEBOT MV A6 coating robots and their related Lesta

only a high-quality finish can guarantee. Although initially

PRODUCTION MANAGER software package.

an underestimated aspect within the sector, the coating of these

Thanks to their self-learning function, Bicelli can now easily record

components has now actually become a key requirement.

in real time the movement of the axes, driven by the operator via a

Bicelli, a company based in Brescia (Italy) that has been producing oil

handle attached to the robotic arm, thus developing an automated

hydraulic cylinders for over fifty years, decided to update its plant in

process that optimises the resources used and provides a uniform,

order to be able to coat large volumes of parts with different shapes

high-quality coating.

and sizes automatically, quickly, and reproducibly.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

A combination of craftsmanship and automation

always with high quality standards, and the

international, automation-oriented one,

Like many small and medium-sized Italian

which enables us to keep serving this rapidly

companies, Bicelli Srl is characterised by

growing market. We are no longer the small

family management combined with consistent

company we used to be in the past, as we

production innovation. Such combination

process hundreds of parts a day, employ

has enabled it to evolve from a small artisan

seventy people, and achieve a yearly turnover

business to a company operating worldwide.

of around twelve million Euros. In addition,

It was founded by Leonello Bicelli in 1968

we are training the third generation of

as a mechanical workshop devoted to the

entrepreneurs who will carry on our family

production of oil hydraulic cylinders and it

tradition and further update this business,”

initially covered an area of around 350 m2 in

says Claudio Bicelli, the son of Leonello

Carpenedolo (Brescia). Over time, it has then

and the General Manager of Bicelli Srl. The

evolved thanks to prudent investments in

evolution of the market has prompted the

automation, which have allowed it to optimise

company to also invest in automation and

production and increase volumes. In 2007,

process integration, in order to be more

Bicelli moved to new premises in Via Meli,

flexible and capable of producing different

which were further expanded in 2020 up to

components quickly and reproducibly.

covering 6,500 m . In 2015, it also established 2

leading to the creation of Bicelli-Geco’s Indian

One product for many different sectors

site, focused on production for the Asian,

The company serves several different

Australian, New Zealand, and US markets.

markets, as oil hydraulic cylinders are

a joint venture with an equal-share partner,

This subsidiary, which was founded with a limited product portfolio and resource pool, was actually able to close last year with a

employed in the industry, in the agricultural and construction machinery sector, and

Oil hydraulic cylinders leaving the pre-treatment tunnel.

in the automotive field. As a result, its

turnover of almost four million Euros thanks to Bicelli’s know-how. “Bicelli Srl has two souls: the artisanal, family-centred one, which allows us to produce different types of hydraulic cylinders

production is highly varied in terms of part Top left: the oil hydraulic cylinders assembly department. Top right: the pre-treatment and coating plant.

geometry, dimensions, and characteristics. However, its catalogue of available products is small, as most components are tailor-made. Every customer analyses its part’s design

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

The plant with the two booths for applying water-based paints.

and requirements with Bicelli, which then manufactures and coats it

Coating: a relatively new but crucial aspect

in-house. “In addition to the quality of our products, what has allowed us

Liquid coating is a relatively new phase in Bicelli’s manufacturing

to evolve is our cross-sectoral approach: we have a diversified clientele,

process. Almost two-thirds of production is painted in black RAL 9005,

which also means that we have had to update our equipment several

while around ten other colours account for the rest. “The need for

times and invest in new technologies in order to meet all the specific

coated end products has gradually developed in our market over the

needs of the markets in which we operate,” adds Bicelli.

last few years. As they are a functional component, one might think

The production of oil hydraulic cylinders takes place in four

that painting oil hydraulic cylinders is unnecessary. However, they

departments. The tubes and bars are initially machined by turning or

are actually a component that is exposed outdoors and subject to

milling. Then, the components are sent to the welding department,

weathering. Therefore, coating them is now an essential requirement,”

which is considered one of the most strategic within the company;

explains Bicelli.

Bicelli’s products contain pressurised oils that can reach 400 bars and

Initially, the company relied on a few painting contractors. In 2010,

welding is essential for them to withstand such a high pressure.

it installed its own manual plant, which in 2016 was dismantled and

Bicelli began automating the process as early as 1995 in order to

replaced by an automatic system, with one booth for the application

increase productivity and ensure high quality: after being welded

of the one-component, water-based base coat through a reciprocator

manually, semi-automatically, or automatically by four welding robots,

and another for the manual application of the two-component top

the cylinders are sent to the assembly department. Finally, most of them

coat. Recently, due to increasing production volumes and the need

are coated.

to improve its coating quality, the company decided to change

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

paint products and further revamp its plant to meet the new requirements. In fact, Bicelli needs to coat around 400 parts a day, with peaks of 600 for small workpieces. In August 2021, the company inaugurated a new automatic plant with a loading and unloading station, a pre-treatment tunnel, a bell oven, and two automatic spray painting booths with Lesta LEBOT MV A6 robots. The plant also includes the Lesta PRODUCTION MANAGER software package, two smart monitors, and a series of photocells to detect the parts arrangement and match the type of component and its position to a specific painting programme,

www.cmautomazione.it

hi-tech

FOCUS ON TECHNOLOGY

conveyors

including loading, unloading, and packaging. An operator manually loads the components onto bars, which take them to the pre-treatment tunnel consisting of cleaning, rinsing, and passivation stations. Afterwards, the parts enter the drying oven and the first coating booth for the application of the base coat. They

Lesta’s self-learning robot applying the base coat.

CM AUTOMAZIONE srl - FA Ganci

Uffici e produzione: Via Monte Bianco 20 - 20833 Giussano (MB) - IT p. +39.0362.314075 - f. +39.0362.861222 - info@cmautomazione.it

SPECIAL ISSUE - PaintExpo

The inside of the base coat application booth.

Lesta’s self-learning robot applying the top coat.

then reach a closed ventilated tunnel for the flash-off stage and the

to obtain sequential programmes. In total, the self-learning process

second booth for the application of the top coat. Finally, they return to

takes less than 5 minutes, so Bicelli Srl has been carrying out several

the oven for drying. In total, the process takes a maximum of 5 hours to

tests in order to find the movements that allow it to apply the paint in

get the cylinders coated, dried, and ready for packaging.

the best possible way.

Self-learning robots

“The self-learning function of Lesta’s robots is very simple and practical. Even operators who were unfamiliar with such machines immediately

A handle with two buttons can be attached to the arm of the robots,

learnt the ropes of it for operations that had previously taken much

under the spray gun. When the button to start the self-learning

longer. After just one day, they were able to operate completely

operation is pressed, the robot releases its arm so that the operator can

independently. Having already had some experience with machine

move it effortlessly, and the machine starts recording all movements

automation we knew what to expect, but we were still positively

until the other button is pressed to end operations. All information is

impressed. The whole self-learning process takes just a few minutes,

then automatically saved with a unique name or aggregated with others

unlike the one used for welding our hydraulic cylinders, which takes up

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

eosmarketing.it

Your partner for green chemical processes Chemtec’s mission is to update tradition. Our revolutionary chemicals are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity. With Chemtec technologies you can replace zinc&iron phosphate. Visit us at PaintExpo 2022 Hall 2, booth 2623

www.chemtecitalia.it

Want to use less energy, get rid of heavy metals and create a safer environment? Want to replace Zinc Phosphate?

Want to save energy, use no water, create no emissions and waste? Want to replace Iron Phosphate?

Choose PRONORTEC

PRONORTEC nanotechnology is a new and innovative chemical process for multi-metal surface treatment, based on the use of organic Phosphorus compounds. It is a 1k process, it doesn’t need any additive to correct pH, nor any concentration of other metals. This process is highly revolutionary both for its ease of use and for the quality of results. It does not create any kind of sludge. It can be applied by spraying, immersion, or nebulization.

Choose TORAN 3®

Single-stage, room temperature multi-metal pre-treatment process, with no VOC emissions, no rinsing, no pre-degreasing, no creation of wastewater or sludge. The unique and innovative anhydrous process is based on organic high-boiling fluids and guarantees degreasing as well as immediate protection against oxidation, leading to excellent performances in the finishing cycle. The TORAN 3® treatment is a valid, less expensive alternative to phospho-degreasing and phosphating and passivating processes.

Choose WASTE WATER TREATMENT SYSTEMS Want to save water, be more sustainable, create less waste?

www.chemtecitalia.it

The combination of Chemtec water treatment equipment (chemical-physical plant, skimmers, filters) with specific chemicals allows the purification and re-use of industrial polluted water in many different industrial applications. Water consumption is significantly cut and water discharge is no more a problem. Waste water are purified and re-circulated instead of discharged to meet the demand of circular economy.

FOCUS ON TECHNOLOGY

P25 column standard or customizable system to hang from the smallest parts to heavy 6-metre long bars

A coated oil hydraulic cylinder waiting to be unloaded and packed.

In the foreground, painted Bicelli components. In the background, parts leaving the pre-treatment tunnel.

to two hours. We sometimes run tests and try to

It was the right choice, because Lesta’s technicians

modify the robots’ movements to find better and

were immediately able to listen to our needs and

better solutions,” indicates Bicelli.

recommend suitable solutions. The plant runs for

Excellent return on investment

HANGING SYSTEMS

fewer hours, so it consumes fewer resources, but it allows us to paint larger volumes than before.

The coating robots supplied by Lesta have enabled

After an initial settling-in phase, the process is

the company to use higher quality coatings but

now running at full capacity and we are completely

with a significant ROI, as the robots operate in a

satisfied with it,” notes Bicelli. “Paradoxically,

targeted way, thus reducing paint dispersion. “We

the efficiency of the new plant has generated a

were introduced to Lesta by Graco, with which we

discontinuity in our flow, as it coats a larger volume

collaborated on mixing the paints supplied by Alcea.

of products than we can assemble.”

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

SPECIAL ISSUE - PaintExpo

The monitor connected to Lesta PRODUCTION MANAGER software.

Conclusions

The paint mixer supplied by Graco.

robots, the amount of paint dispersed during the coating process is

The new coating plant has enabled Bicelli to improve the resistance

indeed minimal.

and quality standards of its oil hydraulic cylinders, as well as making

Bicelli has been striving to update, modernise, and automate its plants

its process more efficient in terms of production capacity, resource

and it has sometimes encountered some difficulties in integrating

consumption, and emissions.

the new machines into its production flow and streamlining the

Moreover, the hanging hooks, previously only positioned every 800

operators’ work: “Lesta’s robots and software, on the other hand, were

mm, can now also be positioned every 400 mm.

implemented perfectly in a short space of time and production is now

Thanks to the photocells that detect the presence and the type of

at full capacity. We could not be more pleased,” states Bicelli.

part to be painted and to the automatic process performed by Lesta’s

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

Rimstock Upgrades Paint Shop Rimstock, the UK’s largest manufacturer of alloy wheels, upgrades its wheel coating system with Graco equipment.

ounded in 1985 and based in West Bromwich in the heart of

A challenge in the paint shop

England, Rimstock designs, manufactures and supplies alloy

Rimstock’s modern paint shop includes an acrylic powder clear coating

wheels to more than 40 countries around the world. It is the UK’s

system and an 11-tank pre-treatment anti-corrosion process. However,

leading prestige wheel manufacturer. In its state-of-the-art facilities

a problem arose in the paint shop. The existing spray guns were

the company takes customers’ initial design concepts through to

giving inconsistent coating results. To rectify this, the supply system

manufacture and distribution.

was having to be continually emptied and refilled for each colour.

Specialising in the design and production of cast and forged wheels,

This continuous flushing of the supply system and then the constant

Rimstock also has full testing facilities available in-house, certified to

adjustment of the spray gun settings was causing a significant and

test to German TÜV approval standards.

unnecessary waste of materials, money, and time.

In 2018, a new plant was commissioned on site, specialising in the

In an attempt to find a better solution, Rimstock spoke with authorised

manufacture of forged alloy wheels. These offer OEMs more complex,

Graco distributor Fluid Handling Solutions in nearby Wolverhampton.

stronger yet lighter forged wheels, which significantly improve vehicle

Nick Turton from FHS proposed a solution incorporating Graco AirPro

braking, handling and fuel economy compared to cast wheels.

Auto spray guns, Triton pumps, and colour change valves.

Rimstock designs, manufactures and supplies alloy wheels to more than 40 countries around the world.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

Graco’s AirPro automatic spray guns are lightweight and compact, and provide consistent spray patterns for a high-quality finish. Models are available with a fluid control knob for precision fluid adjustment, as well as an indexing aircap that provides fast and accurate positioning in either a vertical or horizontal position. These low-pressure, versatile applicators work well for many different materials and applications. High-wear models are available with a carbide needle and nozzle for long life with abrasive materials. Graco’s Triton 1:1 pumps offer a more effective alternative to traditional pressure pots and standard diaphragm pumps. By utilising air-operated diaphragm technology, this spray package applies a high-quality, decorative finish to wood and metal. They are suitable for all types of metal and wood applications and are compatible with a wide range of spray technologies (conventional, HVLP, compliant, electrostatic air spray). Graco’s low and high pressure colour change valves are ideal for a wide range of solvent-borne, water-borne and high-solids materials. A durable, precision-machined manifold offers outstanding performance, while large ¼-inch fluid ports provide less restriction and pressure drop.

Graco’s AirPro automatic spray gun.

PA I N T I N G L I N E S L E A D E R

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

Triton 1:1 pumps offer a more effective alternative to traditional pressure pots and standard diaphragm pumps.

The cartridge-style valve disconnects quickly without removing fluid lines for easier serviceability and reduced maintenance time.

Immediate results

Each colour change valve manifold was supplied with two recirculating paints, dead-end solvent and purge air.

station was fitted with four Graco AirPro Auto guns with knurled micro adjuster (so a total of eight guns). The guns were mounted on adjustable arms which were fixed in position during commissioning. The wheels pass each station and are rotated as

Fluid Handling Solutions installed eight AirPro Auto spray guns, five

the guns spray.

Triton pumps and two colour change valves to spray basecoat and

Rimstock are very pleased with their new wheel painting system. “The

clearcoat onto the rotating wheels at Rimstock.

Graco AirPro Auto guns with indexing fluid needle give more control of

The new paint system was installed on two recirculating basecoat

the spray application and film builds,” explains Mike Wise, Operations

systems, two recirculating clearcoat systems, and one dead-end solvent

Manager, Finishing.

system. Two 4-valve colour change valve manifolds were installed in

“The Triton supply pumps and colour change valves have decreased

the paint booth: one for the basecoat and the other for clearcoat. Each

waste paint and time when changing colours.”

colour change valve manifold was supplied with two recirculating paints, dead-end solvent and purge air. Two automatic spray stations were installed in the paint booth. Each

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

For further information: www.graco.com

we keep an eye on your AUTOMATION needs. vertical&horizontal axis reciprocators | color centers | dimensional detection systems | control panels | accessories

i gent e a i s r a cerc one libe z per

www.reind.it

BRAND-NEW

SPECIAL ISSUE - PaintExpo

quattroClean Cleaning for More Efficient and Sustainable Plastics Coating acp systems AG will showcase a dry, residue-free and efficient solution for cleaning plastic components before coating process at PaintExpo 2022.

The good cleaning effect of the quattroClean snow jet technology is based on the unrivalled two-substance ring nozzle.

he acp systems AG’s quattroClean snow

surface or partial cleaning. The systems,

paint booth - to save space.

jet technology uses climate-neutral

which are based on standard modules, can

Automation is by robot, linear or gantry

carbon dioxide and compressed air as

be designed for manual, partially and fully

system. Part-specific process parameters

cleaning media and removes particulate as

automated cleaning. For painting processes,

such as volume flows for carbon dioxide

well as filmic contaminants in a process-safe

the JetModule is a solution that can be

and compressed air, blasting time, blasting

and reproducible manner.

integrated into a booth - comparable to a

angle and movement sequence - including

The good cleaning effect is based on the

3D movements - can be stored as cleaning

special design of the wear-free two-substance

programs in the system control. Furthermore,

ring nozzle.

the digital controllability of the quattroClean

Compared with conventional wet-chemical

system allows the integration of the cleaning

cleaning, the quattroClean snow jet

process into interlinked and digitalized

technology offers numerous advantages.

production environments.

These include significant savings in investment and operating costs as well as

acp systems AG will exhibit in hall 3, booth

space requirements. Since neither water,

3521.

cleaning chemicals nor drying is required, For further information:

cleaning is resource-saving, energy-efficient and sustainable. Thanks to its scalability, the quattroClean system can be easily adapted to a wide variety of component geometries for full-

The interaction of thermal, mechanical, solvent and sublimation effects ensures that particulate contamination and filmic contamination are removed.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

www.acp-systems.com

BRAND-NEW by MODlFIED ALCOHOL

KANSAI HELIOS at PaintExpo

High performance modified alcohol cleaning machines

High pressure waterjet deburring and cleaning systems

KANSAI HELIOS Group, the coatings supplier, will showcase its new solutions at PaintExpo 2022.

he KANSAI HELIOS Group is a trendsetter in the development of smart, durable, economical and environmentally friendly coating systems. As one of the few system suppliers, it offers complete

systems for industrial coatings throughout Europe. The product range includes liquid coatings, powder coatings, e-coat, gelcoats as well as industrial adhesives and sealants – optimally matched in terms of colour shade, surface finish, gloss level and ageing properties. Customized coating systems for various applications are the company’s specialty. As part of the globally active KANSAI PAINT

Complete integrated in-house build automation

Group, KANSAI HELIOS benefits from access to a global network for services and know-how. And it is constantly expanding competencies thanks to the intensive investments in research and development and formulations of its products in one of the most modern laboratories worldwide. KANSAI HELIOS Group will exhibit at Hall 2, booth 2128 DIVISIONS:

For further information: www.helios-industrialcoatings.com

CLEANING

BLASTING

AUTOMATION

Automation!

Tel. +39 02 97289696

info@itfwashers.com www.itf.it

BRAND-NEW

SPECIAL ISSUE - PaintExpo

ALIT Technologies to Attend PaintExpo 2022 ALIT Technologies announced that it will be among the exhibitors of PaintExpo 2022, the leading trade fair for coating technologies.

LIT Technologies, a specialist in machines and products for the

ALIT’s product range includes the aforementioned Fastrip T2 and T5,

chemical paint stripping of metals, will attend the 2022 edition

Fastrip ISP, the first inline paint stripping system; Fastrip S, the spray

of PaintExpo, which will take place in Karlsruhe, Germany, from

system for paint stripping, and Fastrip AP, the latest addition to the

26 to 29 April. During the fair, ALIT will present its Fastrip T2 range of

ALIT portfolio, developed to chemically paint strip aluminium profiles

compact-sized paint stripping tanks equipped with ultrasonic system

up to 8 meters long. At PaintExpo, visitors will also be able to discover

and integrated heating, and Fastrip T5, the medium-sized paint stripping

Metalstrip, ALIT’s range of paint stripping chemicals.

tank with a capacity of up to 800 litres.

“ALIT offers customers a high added value service: specific consultancy

“PaintExpo 2022 will also be an opportunity to introduce visitors to

on the right product to be adopted based on the paint stripping

the degree of specialization and know-how achieved by ALIT in the

machine in use and the process requirements. This entails a competitive

production of systems and products for the chemical paint stripping of

advantage in terms of the useful life of the chemical product, process

ferrous and non-ferrous metal parts, aluminium and silicone masking.

efficiency, repeatability of results and, last but not least, environmental

The result of over ten years of experience and close collaboration with

sustainability”, continued the company.

major players in various industries, from automotive to metal processing

ALIT Technologies looks forward to meet you at PaintExpo, Stand 3525,

and coating”, stated the company. “All this has made it possible to

Hall 3.

develop a complete range of paint stripping systems that provide a For further information: www.alit-tech.com

solution to all process requirements”.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Fastrip T2.

Fastrip T5.

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www.doerken.com CORROSION EXPERTS

Dörken Coatings GmbH & Co. KG . Wetterstraße 58 . D-58313 Herdecke . Telephone 02330 63243

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

The New Frontier of Small Parts Coating Edited by Imel Codroipo (Udine, Italy)

Imel supplied STS Painting with a coating centre from its new ROTOVER i4-220p range. One of the main innovations brought by this generation of ROTOVER systems is its MES package called i4smallparts, for managing, planning, and controlling the coating process. The collaboration between Imel and STS Painting, however, went beyond the traditional customer-supplier relationship, as STS helped validate the new ROTOVER design by subjecting the machine to the required stress tests.

The new ROTOVER i4-220p centre, consisting of 4 machines and the i4smallparts software, installed by Imel at STS’s paintshop in Chiuduno (Bergamo, Italy).

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The STS’ headquarters in Chiuduno (Bergamo, Italy).

TS has been a job coater of small metal and

products.” Last but not least, the services offered by

plastic parts for over thirty years now. Its

the company also include tumbling coating. Right

knowledge, passion, and will to strive for

from the start of its activity, STS has decided to rely

excellent results have led it to become a benchmark

on Imel Spa (Codroipo, Udine, Italy) as its supplier

supplier recognised for its product and service

of painting machines precisely because it was one

quality. The strength of STS, says entrepreneur

of the very first manufacturers of tumbling coating

Guglielmo Gatti, the founder of the company

machines, with its ROTOVER range. ROTOVER

together with his wife Ernestina, is its ability to meet

systems are built with operators in mind: they are

the demands of different sectors by providing a

flexible, reliable, and easy to use and maintain

wide range of services. “We started in the 1990s

thanks to the high quality of their components and

with a specialised technical enamelling department

assembly.

(in Italian, smaltatura tecnica specializzata, hence

The first machines of this kind were produced in

the acronym STS) capable of carrying out special-

the 1980s and they can still be found in operation

effect colouring operations on all types of small

at various customers, including STS Painting, which

workpieces.

owns twelve of them. Over the years, the ROTOVER

“For parts that require flawless finishes, such as

range has undergone progressive technical

high fashion accessories, we currently have two

improvements and adaptations to new regulations,

automated robotic tray coating systems, complete

while maintaining its original characteristics of

with the latest generation of environmentally friendly

reliability and ease of use. The design and production

curing ovens. In the meantime, we have equipped

of the new ROTOVER i4-220p model, however, have

ourselves with a series of machines and equipment

meant a significant leap forward.

for cleaning and preparing the parts, a phase whose correct design and execution is the result of years

The new ROTOVER i4-220p

of experience and is key to guaranteeing the high

In 2019, Imel kicked off a major research and

quality, uniformity, and durability of the coated

development project for a completely new and

visit us at PaintExpo hall 3 booth 3518

SPECIAL ISSUE - PaintExpo

innovative ROTOVER.

Thanks also to the collaboration with STS Painting, Imel determined its guidelines as follows: • consumption reduction and control; • accuracy of the amount of paint dispensed at any given time; • ease of use and maintenance; • improved, uniform coating; • compliance with safety and environmental regulations; • management of painting cycles (possibility of creating, modifying, and accessing a cycle master file). The system’s mechanical and design aspects had to be innovated in particular. This is why Imel decided to integrate the new ROTOVER i4-220p with a dual-circuit hot air heating system, which enables rapid and uniform heating of the workpieces inside the chamber without affecting the paint spray airflow. This results in the fast attainment of the required temperature set point, with precise temperature maintenance (±1 °C) throughout the spraying and final drying phases. The conventional product spraying system has therefore been replaced with a more powerful one, equipped with an automatic HVLP gun for reduced overspray, fed by a gear pump that delivers the desired flow rate by adjusting the motor revolutions. It is thus possible to know the quantity of product used at any moment, with high precision and in real time. Further innovations arose from the contractors’ need to process all kinds of materials with different types of products. The new ROTOVER i4-220p comes with a variety of baskets that can be fully customised and quickly replaced thanks to the new quick-release system, from the classic Imel baskets with removable sectors to

octagonal or rounded baskets in all sizes. This allows even small batches to be processed within the same machine, without the need for different plant sizes. The machine is also ATEX-certified, so that any type of solvent-based product can be sprayed safely without any spillage of toxic substances that could damage the operators’ health.

Interior of the new ROTOVER i4-220p’s basket. The i4smallparts platform by Imel enables to manage the ROTOVER centre, consisting of one to several machines, and monitor production.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Beyond mechanics: the i4smallparts platform and the interconnection features

orders to be loaded and batch treatment to be planned by distributing

Thanks to the experience gained with the development of its own

we have moved beyond the concept of “machine”: we now have an

platform 4.0 for the management of the big data collected by coating

innovative system that enables to work with the same simplicity as the

plants, called i4paintshop, Imel’s R&D department developed the

old generation of ROTOVER plants, while at the same time guaranteeing

i4smallparts MES package for the management, planning, and control of

repeatability thanks to the presence of a constantly updated cycle

the ROTOVER plants. Connected to various databases (customer master

database.”

data, product master data, cycle-recipe master data), this platform

At the end of each cycle, the product data sheet is automatically printed

enables to manage the ROTOVER centre, consisting of one to several

with all the actual process data from the machine and any changes

machines, and monitor production.

made by the operator to the original recipe. This allows the consultation

Guglielmo Gatti, who participated in the production tests himself,

of already-produced batches, so that any non-conformities found by

describes this solution as follows: “Configuration is simple, user friendly,

end customers can be tackled objectively.

and effective. The operators interact with easy-to-use control PLC

The versatility of i4smallparts also allows for partial customisation and

machine that also allows stand-alone operation, with the possibility

enables to interface it with ERP systems already present in the company.

of storing recipes locally. This can be a first investment for those

If a company is not equipped with ERP, this platform can actually act

companies that want to start with one machine. However, when

as both MES and ERP system. Incidentally, this makes it eligible for the

connected to various machines, i4smallparts also enables production

benefits provided by the Italian “Transition 4.0” program.

the required coating programmes to the different machines. Ultimately,

We will be attending

Hall 3, Stand 3133

SPECIAL ISSUE - PaintExpo

Among the ROTOVER’s benefits, there is the improved coating uniformity.

R&D collaboration between Imel and STS Painting

product-optimised recipes and send them directly to the customers’

The project validation phase began in early 2021. STS decided to

machines. We also use this service during the offer phase, when a

cooperate by taking charge of the stress tests, which led to the

potential customer sends us its product samples.”

validation of the project in June of the same year. Federico Scian, product manager at Imel, describes the development of these stress

Design

tests: “We subjected the machine to continuous production tests and

After two years of work in the search for the optimal technical solution

checked with an operator how easy the software was to use: loading

and the construction of three prototypes, Imel set itself the goal

existing cycles, modifying them, storing them, and creating them from

of offering to the market an actual design product and not just a

scratch, but also controlling coating quality by safely inspecting the parts

“machine”. This led to a collaboration with industrial designer Luca

during spraying. We even simulated crash situations to optimise reboot

Floreanini, with whom Imel developed and built the final version of

times. I can definitely say that we are pleased with the results, and the

its system. “Industrial design is one of the strengths of the Italian

orders already received prove us right.”

manufacturing sector. It brings a direct commercial advantage, as well

Service Federico Scian adds: “We set ourselves the objective of offering a simple and complete solution. However, this does not detract from the fact

as offering the pleasure to admire a product beyond its technology and functionality aspects,” states Imel general manager, Stefano Bianchin.

that the engine of this system is complex and requires a higher level of

STS is pleased with the results

control. This is why both the i4smallparts management system and each

As proof of customer satisfaction, this collaboration continues: in June,

individual machine are interconnected to Imel’s service centre in order

STS Painting installed its own new ROTOVER station, consisting of four

to enable us to diagnose any problems in real time. Furthermore, since

machines interconnected to the i4smallparts system.

Imel’s premises are equipped with a test centre, we are able to develop

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

WE WILL BE AT:

OUR STAND IS LOCATED: Hall 3 - Stand 3511

Some keys printed, laser engraved, and coated by Barnem Tecnologie Plastiche Srl.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

Barnem Invested in AR Coating for its Plastic Touch Screens: The Future of the Automotive Industry Giorgia Ricchiuti, ipcm®

Touch screens for car interiors with top layers in plastic instead of glass: is it a possible solution? Yes, it is, thanks to the innovation introduced by Barnem Tecnologie Plastiche Srl, a firm from Brescia (Italy) that has been working in the automotive sector for fifty years and that entrusted Railtechniek Van Herwijnen BV, a Netherlands multinational company with offices in Legnago (Verona, Italy) and a production plant in Romano D’Ezzelino (Vicenza, Italy), and Airmadi Painting Srl (Castelnuovo del Garda, Verona) with the supply of a UV AR coating plant featuring a power&free conveyor equipped with a frame tilting system.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

he automotive sector is constantly

evolving. Continuous design innovation, the implementation of new digital

technologies, and increasing consumer demands for customisation are forcing manufacturers to adapt to complex market requirements and sometimes anticipate future trends. This is the case with Barnem Tecnologie Plastiche Srl, a company from Brescia (Italy) that has been managing by the two brothers Peter and Mauro Barensfeld, and operating in the automotive market for over half a century as a Tier 2 supplier, i.e. a producer of sub-components for Tier 1 manufacturers, which in turn directly interface with OEM car makers. Barnem was established as a mould producer and then evolved into a manufacturer of finished products. Now a benchmark for many companies, Barnem is recognised as a reliable supplier of cosmetic plastic components. Its industrialisation know-how includes the

The loading station with a 4-sided loading spindle hooked on a bar.

production and finishing of keys, controls, touch screens, and other human-machine interface elements. With its two factories and

departments devoted to mould construction, moulding, coating, chrome plating, laser engraving, and assembly, this company can industrialise and produce 1K, 2K, and 3K moulded plastic parts that can be decorated with solvent-based, water-based, or UV paints or even chrome plated or PVD coated, laser engraved, and assembled based on customer drawings. “Our customers include Joyson, Denso, Magna, BHTC, and Magneti Marelli. Most of them are based abroad, with around 60% of our production crossing the Italian borders,” says Marcello Chessari, Barnem’s Business Development manager. “Our customers recognise our ability to anticipate market trends and OEM requirements, a skill we have mastered to the point where we are the first to launch innovative products onto the market. The latest challenge won, and the reason for the installation of our fourth coating plant, was the production of

The first station tilts the spindle into a horizontal position to allow guided 360° rotation during treatment.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

touch screens with the top layer in plastic instead of glass. The plant we commissioned from Airmadi Painting Srl, together with Railtechniek Van Herwijnen BV for part handling, is in fact devoted solely to applying anti-reflection (AR) coatings and scratchresistant UV coatings on touch screens and other cosmetic plastic components of the latest generation for car interiors. In particular, we asked these suppliers to design a system using solvent-free UV products with 100 per cent dry residue, in order to make our finishing operations even greener. In addition, we required high flexibility in polymerisation through the integration of the UV lamp station with another station using infrared panels in order to also apply twocomponent outdoor coatings, which require © ipcm

A detail of the tilting system developed by Railtechniek.

high resistance to sunlight.”

From design to coating “As well as developing production processes for components designed from 2D and 3D drawings supplied by customers, which is a key part of our business, we have a moulding department with around 26 presses ranging from 30 to 450 tonnes,” explains Chessari. After machining, the parts reach the coating department, the core of the factory. There are 4 automated systems installed here, 2 for large batches of plastic parts, 1 for small batches, and the fourth and most recent one devoted to AR coating, which applies UV paints in one coat with around 20 different programmes depending on the product used. “This plant performs 4 process stages, beginning with an initial cleaning stage with CO2 – a technology chosen because it leaves the parts completely dry, which is key to

the quality of the subsequent UV coating phase, as it would be jeopardised by any surface moisture residue. The second stage is the robotic application of UV coatings, in © ipcm

Once in a horizontal position and with only two contact points, the spindle is completely free to rotate independently of the next one.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

a station located after a buffer that isolates the cleaning area from the coating area,

FOCUS ON TECHNOLOGY

GLOBAL SOLUTIONS FOR WATER TREATMENT

The CO2 cleaning station.

which is pressurised and has absolute filters for maximum air

with a complete service that includes system design manufacturing installation technical support chemicals

cleanliness. The 4-axis robots are hanging, so that the work surface is completely clear. The spray application is carried out by ABB’s latest generation of rotating bells”, adds Marcello Chessari. “One of the characteristics required of this line’s paint application system was the ability to produce very thin thicknesses, because AR coatings range between 15 and 20 microns. Therefore, it was essential to achieve perfect calibration between the constant flow rate of the paint feeding pump and extreme atomisation. “The third stage of the process is baking, in the station featuring infrared panels. We opted to install panels with more power than the energy required for polymerising the paints currently in use, because we expect that the coatings being developed now will require more energy for baking. Therefore, we can say that this plant is ready to meet both the current and future needs of AR coating. We took the same approach for the fourth process step, namely final polymerisation using UV lamps. The group of lamps is adjustable both in height and in terms of output (power and wavelength frequency), just like the IR lamps. “The plant was designed to ensure maximum flexibility

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in coating depending on the chemical product used. It is interfaced with our MES system, and all operating parameters are recorded on our computer system so that we can guarantee perfect traceability of all stages.”

Via E. Torricelli, 79 - Z.I. Fossatone 40059 MEDICINA (BO) Tel +39 051 856263 info@hydroitalia.com www.hydroitalia.com

SPECIAL ISSUE - PaintExpo

Focus on the inverted conveyor “According to the original design, Barnem’s plant should have been equipped with a much simpler inverted conveyor than the one we installed,” notes Daniele Adorno, senior key account manager at Railtechniek. “However, during the design phase, when we superimposed the layout of the plant on the building’s one, we saw the clear need to optimise space. Therefore, we supplied an inverted power&free two-rail conveyor in which we integrated a very interesting frame tilting system.” “Due to the extreme variety of parts produced by Barnem, which can vary in size from a few centimetres up to over one metre, handling is carried out using bars consisting of 4 frames, commonly called spindles. Each of these is independent of the others, in order to guarantee full flexibility in terms of loaded product, rotation, route, © ipcm

and treatment programme. Each spindle is The pressurised, dry-filter paint application booth designed by Airmadi together with the rest of the coating plant.

1,500 mm high and has 4 loading faces for carrying a maximum of 24 workpieces. The bar is 1,250 mm long and can accommodate up to 4 spindles side by side; it has a rotation diameter of 300 cm and 4 rotation positions: 0°, 90°, 180°, and 360°,” indicates Adorno. “At the loading station, the spindle is hooked to the bar in a vertical position, with a very simple insertion system also designed by Railtechniek. Prior to entering the CO2 cleaning chamber, the spindle is

tilted to undergo the treatment process in a horizontal position, allowing it to rotate through 360°, independent of the spindles before and after it. This has saved 1,500 mm of space at the loading and unloading areas, where the spindles are handled vertically: at the end of the coating process, that is, after the UV polymerisation station, a second tilting system brings the spindles back upright before the unloading bay. “Power&free conveyors are based on a two-rail system in which the drive chain runs

in the upper rail (Power) while the lower The infrared polymerisation station.

rail (Free) carries the trolleys that transport the parts. We designed special trolleys for

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

Zaniolo CdA-03.22

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SPECIAL ISSUE - PaintExpo

The UV polymerisation station.

Barnem’s conveyor because, even though they transport very light

distance of the part from them, the speed and time of rotation of the

workpieces to be coated, the load bars they carry are integrated with

spindle, the number of faces of the spindle being treated, and so on.

the tilting system, reaching a total load weight of 250 kg. Another very

The entire system 4.0 was designed by the Railtechniek design team in

important aspect that required a lot of design effort was ensuring

conjunction with Airmadi and with the final endorsement of Barnem,

maximum precision of the rotation mechanisms and maximum

to guarantee maximum flexibility and customisation.

positioning repeatability. This system is therefore very compact, but also highly complex in terms of workpiece handling.”

Industry 4.0

The plant’s technical features “One of the aspects we worked on most during the design phase,” says Giovanni Genovese from Airmadi, “was that of aeraulics, with the

The line is controlled by the Airmadi system’s Master PLC, the only

filtration system including dry filters and absolute filters to ensure

interface between the coating plant and Barnem’s MES. The Master

perfectly clean air in the booth and optimum aeraulic balance. On

PLC cascade-interfaces with the Slave PLCs of the conveyor, the

the coating booth, we have installed an ad hoc air treatment unit

paint application system, and the CO2 cleaning system. Railtechniek

that manages temperature and humidity, whereas for the rest of the

developed the entire Industry 4.0-oriented bar management interface

system only temperature is managed. The system is equipped with

with QR codes and a system of scanner guns used for loading,

a series of inverters and rolling shutters that automatically manage

unloading, and writing output files. This system handles all the smart

all feeding and extraction ducts through temperature and flow

operations involved in virtually associating each QR code to a bar or

rate sensors. The automatic system can handle any filter clogging

to just one of its 4 frames. In this way, within the same load bar, each

issue in the air treatment unit as well as in the booth’s feeding and

spindle has its own QR code that allows recording numerous process

extraction ducts and in the system as a whole. Like Railtechniek,

parameters, including the power of the UV lamps and IR panels, the

we did not stop at standard solutions, but took the mechanical

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

and electronic engineering aspects of the

system to extremes, interfacing it with the Industry 4.0-oriented management interface developed by them.” The system management software package was conceived, designed, and implemented by Airmadi, obviously in collaboration with the customer. As a whole, the installed line was the result of an in-depth collaboration among the three parties. “With this investment, we combined the elements specified by Barnem, namely the CO2 cleaning system

and the coating feeding and management system, with the equipment supplied by Airmadi, which acted as the prime contractor by choosing Railtechniek as the supplier of the conveyor,” summarises Marcello Chessari. “Airmadi was chosen through a tender at the end of 2019 and it was given very detailed specifications that precisely

The second tilting station where the spindle is placed vertically before reaching the unloading area.

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• Combination with PXM powder center: Automatic fresh powder supply and integrated system control via 15.6 inch touchscreen

Visit us at PaintExpo Hall 3, Booth 3330.

SPECIAL ISSUE - PaintExpo

From left to right, Giovanni Genovese from Airmadi, Marcello Chessari from Barnem, and Daniele Adorno from Railtechniek.

defined the process steps to be performed, the type of coating

applications. The decision to implement this plant three years ago was

products to be applied, the power required for both air treatment

based on a business strategy aimed at anticipating the needs of the

and polymerisation, and the cycle times. We opted for these suppliers

market,” says Marcello Chessari.

because they proved able to ensure the operational flexibility that our

“Touch screens are the alternative to keys, and will be even more

project needed, as well as a very positive benefit-cost ratio. Obviously,

so in the next few years, even in cars. Barnem is ready to meet all

the implementation and try-out phase required some additional

current and future requirements for touch screen finishing. We are

adjustments, but it was precisely here that such flexibility emerged.”

also assessing the implementation of a sputtering process for anti-fog

A future-oriented company “The market is already demanding AR coatings: we receive many requests from both Italian and foreign customers for clear coat

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

treatment, to be applied to the inside of touch screens and combined with AR coating, which is used on the outside, to provide a premium product for the automotive market of the future.”

FILTRAZIONE PER IMPIANTI DI VERNICIATURA FILTERING FOR FINISHING LINES

rotoli, pannelli e celle in fibra di vetro

rolls, panels and cells of glass fiber

celle filtranti per alte temperature

filtering cells for high temperatures

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FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

Powder Pre-Finishing with Self-Learning Robots: The Key Solution for Finishing Fael LUCE’s Customised Products Monica Fumagalli, ipcm®

Fael, a company specialising in the design and manufacture of high-wattage lighting systems, has integrated its new coating line 4.0 with two self-learning robots supplied by Epistolio for the powder pre-finishing of the finned casings of its lighting systems – a convincing solution thanks to its ease of programming and high application performance.

Fael is specialising in the design and manufacture of high-wattage lighting systems.

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

elf-learning devices are becoming increasingly common in the manufacturing industry. What is

generally referred to as “self-learning” is a variant of the traditional programming system, giving a machine the ability to record data autonomously and acquire paths, shapes, and forms in order to repeat actions and perform relevant machining operations. In production departments, the self-learning mode simplifies machine programming to such an extent that operators do not even need any specific computer training. “The management of robot stations should never be difficult or complex,” emphasises Andrea Stopazzola, who manages production at Fael Spa (Agrate, Monza e Brianza, Italy), a company active for almost sixty years in the field of high-wattage lighting systems. “On the

contrary, like all the other technical measures

General view of Fael’s new coating plant 4.0.

that a company puts in place to streamline its production flow and make it more effective, it should be intuitive and user-friendly, especially in a largely digitalised production environment such as the one Fael is developing in compliance with the Industry 4.0 parameters.” In fact, the implementation of two self-learning robots supplied by Epistolio Srl (Casciago, Varese, Italy) for powder pre-finishing has changed the Fael operators’ approach to painting, improving the quality of coatings and speeding up application.

Light: Fael’s raw material Fael Luce has established itself as a leading supplier of lighting systems for large recreational and sports areas, roadside reinforcement, and industrial and commercial facilities. “Cavalier Arnaldo Toschi founded Fael in 1965,” says Cristina Sesini, the marketing & communication manager, to introduce the long history of the company. “In the 1990s, the firm was taken over by the Parravicini family, who is still at the helm today. The new management changed the company’s vision, which has since expanded and

The 10-stage pre-treatment tunnel (right) and the drying oven (left).

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

SPECIAL ISSUE - PaintExpo

focused on foreign markets, initiating a process of internationalisation. During that time, the Lighmaster One floodlight was launched, enabling Fael to enter the high-power lighting sector: this lighting system is in fact able to reach 2000W with the discharge lamp technology. From the second decade of the 2000s onwards, LED technology has begun to spread and become more and more predominant, so the company has started to convert all its production lines. Initially, we kept producing our floodlight casings as we did with the discharge lamp technology, but we gradually changed them as the size of the LED plates increased and trends in the aesthetics and design of floodlights evolved. Fael now manufactures the most innovative and sustainable LED lighting systems on the market.” This conversion, however, involved an issue in terms of surface treatment. “The constraint of LED technology,” explains Stopazzola, “is the need to © Epistolio

prevent excessive heat build-up in the area around the plate and inside the appliance. That is why we

The first pre-finishing station with a 6-axis Epistolio robot and the application management module.

modified our casings by adding a fin system that, while facilitating heat dissipation, nevertheless complicates the process of applying powder paint, which has to cover also the difficult-to-reach areas in the undercuts of the fins. In order to improve our coating quality and meet the expectations of our customers, our Management decided to take action and replace the old painting plant, which had been in operation for forty years, with a new one, allocating to it a new area of the 4,000 m2wide building and increasing its capacity by 40%.” “Now, with the construction of this new department, our production plant covers an area of 16,500 m2,” indicates Sesini. “This construction was considered so important that the Parravicini family decided to start to build it in one of the most difficult recent periods, during the lockdown at the beginning of 2020.”

The MRK 6.1 robot installed before the primer application booth.

From desert sand to Nordic cold: customised products for different applications Fael uses a special aluminium alloy for its floodlights located in the most extreme parts

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

of the world, from seaports to desert areas, from roadside areas in

according to the type of product to be coated. “We have to mask some

severe weather conditions to airports in Northern Europe. “We export

surfaces to prevent the paint applied in the areas closest to the LED

and install our floodlights all over the world, so they have to be able to

from affecting heat distribution: that is why we need ad hoc hooks

withstand the most extreme temperatures. This particular aluminium

for each type of product.” After manual loading, the parts are taken

alloy guarantees the best performance level in terms of both paint

to a 10-stage pre-treatment tunnel, a drying oven, 4 powder coating

film adhesion and sealing,” states Stopazzola. “Fael’s technical staff

application booths preceded by the two stations equipped with Epistolio

personally take care of the design and construction of moulds and the

robots, a curing oven where they sit at 190°C for 20 minutes, and the

purchase of raw materials, which we then supply to external companies

unloading station. Fael coats 100% of its production, which, in addition

for the moulding of our casings. As soon as these reach our premises,

to the casings, consisting of upper and lower shells with maximum

they are thoroughly checked before being sent to the machining

dimensions of 500x600 mm, includes various smaller accessories such

department, which currently consists of 15 lines.”

as brackets and steering tubes. The production process ends with

In the high-wattage LED lighting sector, the trend is also towards

the assembly of the lighting systems and final testing, where both the

product customisation. “Whereas LED projectors were standard

electrical and optical elements of the floodlights are checked before

products when they first came onto the market, today our partners

shipment.

provide us with specifications on both their operation and their aesthetic characteristics. It is therefore easy to understand how

Innovation in the application system

important coating is for us, nowadays.”

The previous painting system was designed for one-coat application. On

The new painting plant is equipped with a one-rail conveyor designed

the other hand, “The current plant enables us to apply both primers and

and installed by Futura Convogliatori Aerei, with bars positioned

topcoats in four booths, which we divided as follows: a booth for primer

approximately 40 cm apart and 600 workpiece-holding hooks selected

application, a booth for manual application on samples or small batches,

www.freilacke.de

SPECIAL ISSUE - PaintExpo

a booth with a 12-minutes quick colour change system for the application of different colours, and a booth applying the silver colour, which accounts for 80% of our production.” One of the most critical issues encountered when coating casings is the Faraday cage effect that occurs in the undercuts of fins. “In those areas, the paint has difficulty penetrating. This is why we have chosen to use triboelectric guns for the primer application, a technology that could be described as outdated but that is ideal for our needs. At the same time, we integrated it with the dense phase technology of the last generation Nordson HD guns installed in the two topcoat application booths (multicolour and silver). We installed the two Epistolio robots before the primer application booth and the silver colour application one: the pre-finishing operation they carry out ensures more effective paint penetration into the undercuts and greater © ipcm

The intervention of the robot before the primer application enables the powder to penetrate even the most critical areas, such as the undercuts of fins.

coating uniformity. Previously, this was done manually, but the increase in volumes brought

Application of the primer with triboelectric guns.

by the new production lines meant that this operation, which is crucial to the final quality of our casings, also had to be automated.”

Self-learning robotics: the solution that convinced Fael “When Fael contacted us, its needs were similar to those of many of our customers,” explains Epistolio Srl sales manager, Luca Venturini, “namely production flow optimisation and coating quality improvement. However, we decided to take a different route than the one we take with our usual partners. We wanted to prove that, contrary to popular belief, the integration of one or more robots into a production system does not represent a complication in terms of programming operational interventions, but rather a simplification. In order to do this, we carried out a pre-test, during which we © ipcm

One of the casings after primer application.

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installed one of our robots on the previous system and performed a live demonstration of its operation.

FOCUS ON TECHNOLOGY

The second robotic pre-finishing station.

Topcoat application with 6 guns.

“In a company like Fael, increasingly focused on product

training for the application during the actual

differentiation, off-line programming would indeed

production phase.”

require a lot of time and computer-savvy operators.

The two 6-axis robots installed belong to Epistolio’s

Self-learning programming, on the other hand, is simple

MRK 6.1 series. “These machines have been in

and practical: thanks to the use of a specially designed,

great demand in recent years for the pre-finishing

ergonomic joystick complete with programmable

of powder-coated products, confirms Venturini,

buttons, the operator can manage programming

“because of their ease of programming and their

from the spraying point along the whole shape of

seamless integration with company software, as

the workpiece. It is therefore the ideal solution and it

they are Industry 4.0-ready.”

does not require any special training, which is what “Our operators,” notes Stopazzola, “were very

Digitalisation and the environment: Fael’s present and future

impressed by the simplicity and flexibility of this

Fael’s next objective is the digitisation of all

operation, which does not require a programmer but

coating operations. “We have taken steps to

rather a good painter who can guide the robot, allowing

collect information from all the automatic devices

it to memorise the correct application movements and

in the system on one display and thus make it

repeat them. The pre-test also served as preliminary

easier to manage. This will not only allow us to

convinced Fael’s coating staff.”

SPECIAL ISSUE - PaintExpo

monitor sensitive data such as tank and oven

system connected to heat exchangers to

temperatures and conveyor speed, but also to

the reverse osmosis system that produces

record tracking data and archive them so that,

demineralised water for 4 of the 10 pre-

in the event of a critical issue, the defective

treatment tanks, from the water treatment

operation can be traced back exactly and

plant for recovering waste water and disposing

quickly. In addition, for all devices – first of all

of sludge to the measures taken to reduce

the two robots – the supplier will be able to

product consumption, as in the case of

interface with the plant supervisor and carry

powder coatings thanks to the HD technology.

out remote diagnostics.”

All of this is controlled automatically by the

“Our factory’s digitalisation project started with

management system 4.0.

the new coating line and it will extend to the

A component coated with the silver colour, which accounts for 80% of Fael’s production.

102

entire production department,” says Sesini. “At

“Fael is accustomed to manufacturing and

the same time, we are focussing on another

supplying all its stakeholders with products

aspect that has always characterised Fael’s

of higher quality than the standard,” states

policy, namely environmental sustainability,

Stopazzola. “All our efforts are aimed at

as confirmed by the presence of photovoltaic

achieving high functional and qualitative

panels on our building’s roof, with which we

results, thanks to which we can participate

have been able to produce the electricity

in both public and private tenders with very

for our production needs for years now.

strict requirements also in terms of surface

Recently, we have also been recognised by

coatings. Epistolio’s technology has brought us

the Lombardy Region as circular economy

advantages both in terms of application speed

operators because, from the design of our

and management and in terms of coating

lighting systems to their distribution on

results, thanks to our operators being able to

the market, our entire process is aimed at

teach the robots how to reach even the most

recovering resources.”

complex surface areas. This is the essence of

Specifically in the coating department,

the perfect interaction between human and

recovery is focused on reducing energy

machine and of what it actually means for us

consumption, from the centralised heating

to adapt to the parameters of Industry 4.0.”

N. 74 - MARCH/APRIL 2022 - international PAINT&COATING magazine

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A woodworking machine manufactured by Felder Group.

FOCUS ON TECHNOLOGY

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Felder: Sustainability, Water Recycling, and Energy Saving in the Production of Woodworking and Metalworking Machinery, with the Atmospheric Pressure Mechanical Compression Evaporation Technology Alessia Venturi, ipcm®

Saving resources, energy, disposal costs, and labour for pre-treatment while raising rinse water quality? It is possible, with a closed-loop water treatment system downstream of the pre-treatment station, which allows water to be recirculated after purification. By implementing an atmospheric pressure mechanical compression evaporator built by MKR Metzger into its system, Felder Group (Hall in Tirol, Austria) has achieved an ambitious goal: reducing water consumption and saving 70% of disposal costs through ultra-low energy technology.

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FOCUS ON TECHNOLOGY

dgebanders, wide belt sanding machines, sliding table saws, sawshapers, intake systems, hot presses,

The 5-stage pre-treatment system of the coating line for small and medium-sized parts.

brushing machines, bandsaws, jointer-

most beautiful mountain areas in Europe, motivates Felder to keep further improving its plants, processes, and production © ipcm

technologies based on two approaches:

planers, boring and mortising machines, and

energy efficiency and the saving of natural

combined systems: these terms, which define

resources.

a range of machines and tools for processing

The most recent investment in this field

wood, aluminium, and plastics for both the

involved the treatment and reuse of the water

industry and the DIY sector, represent the

used in its powder coating pre-treatment

core business of Felder Group, a Tyrolean

process, a production phase to which Felder

company headquartered on the outskirts

has devoted two semi-automatic lines. The

of Innsbruck (Austria) and a long-standing

implementation of an atmospheric pressure

manufacturer of machine tools, now in the

mechanical compression evaporator built by

third generation of its founding family.

MKR Metzger (Germany), represented in Italy

Driven by a tireless spirit of innovation,

and Austria by FI.T. Filtration Technologies Srl

Felder Group develops smart solutions and

(Bolzano, Italy), has enabled Felder to limit its

products for all users who want more than

water consumption and reduce its disposal

just a machine. From a small pioneer in the

costs by 70% through ultra-low energy

sector to a technologically advanced industry

technology.

operating on an international scale, Felder has been maintaining the same values for

Vertically integrated production

decades, especially the will to provide each

Sheet metal processing, laser cutting,

customer with the perfect tool for their

metalworking, painting, storage of the

success story. Indeed, Felder’s product quality

finished machines in an automated vertical

is also based on close cooperation with its

warehouse, packaging, and shipping: Felder’s

customers, thanks to which the company can

production is fully vertically integrated, with

incorporate any requirement into innovative

reduced reliance on third-party suppliers.

and customised machine concepts.

This allows the company to maintain total

Its strong environmental awareness, alto

and constant control over its products, from

tied to being surrounded by one of the

the reception of raw material through to

The powder application booth of the coating line for small and medium-sized parts.

The powder application booth of the coating line for large parts.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

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SPECIAL ISSUE - PaintExpo

The atmospheric-pressure mechanical compression evaporator manufactured by MKR Metzger.

The system for sucking in water from the underground storage tank.

The inside of the evaporator.

The water treatment flow designed by FI.T. Filtration Technologies Srl.

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FOCUS ON TECHNOLOGY

finishing. For the latter phase in particular, it uses two semi-automatic powder coating lines that give it the necessary flexibility in terms of parts size and shape, substrates to be coated, and applied colours. The oldest line is devoted to painting small and medium-sized parts. This is a step-by-step system with a 5-stage pre-treatment cycle: phospho-degreasing, two cascade rinses with osmosis water, and two cascade rinses using a mixture of distilled and osmosis water since when FI.T. has installed the MKR evaporator. After drying in an oven at 40 °C, the parts enter a cooling area and then reach the powder application booth and the curing oven. “This system is very flexible,” says Felder Group coating manager, Michael Brunner. “We mainly apply ten standard colours, but we can do any tint to order, as we can change colour even from one load bar to another.”

The concentrate collection tank.

The second semi-automatic plant has the same configuration as the first, but it coats

operation, and therefore of its coatings,

products in Italy and Austria. “The rinsing

larger workpieces.

through the use of high-quality distilled water.

water is stored in an underground tank. From

This is a step-by-step system as well, with a

here, the treatment system sucks it in and,

that includes phospho-degreasing and two

An efficient, easy-to-manage, and flexible water treatment system

cascade rinses with osmosis water and

“The MKR mechanical compression

produced by the evaporator returns to the

distilled water from the evaporator.

evaporator I installed at Felder treats both

pre-treatment line.”

For Felder, the inclusion of the MKR

coating lines’ rinse water volume,” explains

“Our evaporator produces a very pure

evaporator was not only a way of reusing pre-

Klemens Schwienbacher, the owner of FI.T.

distillate that can be reused as pure process

treatment water, thus dramatically reducing

Filtration Technologies Srl, a small company

water,” indicates René Schumann, the

the consumption of this natural resource

specialising in consulting and the supply of

sales manager of MKR Meztger (Monheim,

while lowering disposal costs, but also of

filtration and water treatment systems, which

Germany), an innovative company run

increasing the quality of its pre-treatment

holds the exclusive rights for MKR Metzger

by the second generation of its founding

3-stage multi-metal pre-treatment process

after neutralisation with caustic soda, conveys it to the evaporator. Afterwards, the distillate

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family, which, in addition to highly innovative evaporators, offers a complete range of water treatment products. “The distillate leaving the evaporator feeds the last rinsing stage of both pre-treatment lines and from there it cascade-feeds the upstream stages, up to phospho-degreasing. The closed-loop water treatment system only externally disposes of the evaporator concentrate, which is collected in small 1000-litre tanks.” “The evaporator installed at Felder has a capacity of 200 l/h, it operates 24 hours a day with continuous discharge of concentrate, and it performs an automatic cleaning cycle after 200 hours of operation,” adds Klemens. “The evaporator’s output is managed automatically. When there is little water to treat, the flow rate automatically decreases, as the machine can operate with less than

The evaporator’s control panel.

half the original flow rate.” “A major advantage of MKR’s mechanical © ipcm

compression evaporation technology compared with other technologies on the market, such as vacuum evaporation, is the considerable energy saving it guarantees,” says Schumann. “Moreover, evaporation at atmospheric pressure further reduces energy consumption. An additional advantage of our larger evaporators is the possibility of using the resulting thermal energy to feed the machine with steam.” Klemens notes: “This technological aspect is very interesting for large evaporators; however, it cannot be applied to Felder’s evaporator, since it only draws 10 kW.” “From the installation of the evaporator last August until the end of December, we have treated 350 m3 of incoming water and disposed of only 14 m3 of concentrate, that is, 4% of the total waste water volume. We have achieved 70% economic savings compared with our previous disposal costs, including the rebuilding of the phospho-degreasing bath, whose sludge (about 6 m3) is not treated by

The pH control system.

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the evaporator but is disposed of externally twice a year,” explains Michael Brunner from

FOCUS ON TECHNOLOGY

From left to right, Michael Brunner from Felder Group, Klemens Schwienbacher from FI.T. Srl, and René Schumann from MKR Metzger.

Felder. “Undoubtedly, the investment in our water treatment system

of their technical service staff. We are very happy with our choice,

with the MKR evaporator has brought us a considerable advantage

especially since their support was crucial during the first months

in terms of running costs as well as water saving, which is key to

of the machine’s commissioning. FI.T. is a technical partner that

environmental sustainability. A zero liquid discharge operation was

responds immediately to any call and MKR’s technicians are always

our main goal, and I must say that we achieved it brilliantly! We opted

on the ground in a very short time.”

for FI.T. and MKR out of three different offers. The reason for this

“In my long experience in the water treatment sector, I have met

was not the investment cost, but the sound project developed jointly,

many customers who are great experts in their trade as coaters,”

the assistance provided during the start-up phase, and the proximity

says Klemens Schwienbacher from FI.T.

SURFACE TREATMENT AND COATING PLANTS QUALITY AND INNOVATION BEYOND THE SURFACE O.M.SA. s.r.l. Via Cimabue, 16 | Fraz. MONTESIRO 20842 BESANA in BRIANZA (MB) | ITALY info@omsasrl.com | www.omsasrl.com

SPECIAL ISSUE - PaintExpo

Conclusions “Many of them know that their pre-treatment processes have a few

Sustainability, environmental awareness, and efficient use of resources

pain points, often related to the quality of rinses, but they do not want

are Felder Group’s daily business. 100% of the electricity used in its

to deal with them, because they are afraid of having to install a new

factory comes from renewable energy sources; the building has a

system complete with an evaporator. However, I can take the time

complex thermal energy recovery system; its production plants are

to analyse their issues in detail and find the right technical solution

among the most modern; and the optimisation of energy consumption

together with them. Moreover, considerable improvements can

saves 320,000 kilograms of carbon monoxide per year, equal to the

often be found just by optimising the water flow or by installing an oil

CO2 output of 25 homes. The closed-loop water treatment system

separator, a dirt separator, or a demineraliser.”

implemented by FI.T with MKR technology is its latest feather in the cap in terms of sustainability.

MKR technology: high purification efficiency combined with energy saving The machine supplied to Felder Group is an ET 200 model, with a production capacity of 200 litres of distillate per hour. It is a small machine in the MKR range and, as it has a low flow rate, it only draws 10 kW of specific energy (50 Wh/litre). MKR’s evaporators work on the principle of mechanical steam compression, which consumes very little energy. In addition, unlike other systems, they operate at atmospheric pressure, which further reduces energy consumption. The combination of these two technologies offers several advantages, including as follows: - Depending on the size of the machine, electricity consumption is reduced up to 35 Wh/litre. - With an evaporation temperature of 100 °C and a steam temperature of 105-110 °C, the system also performs a bactericidal action. - With a temperature difference of 5 to 10 °C between the steam side and the waste water side, fouling of the machine’s heat exchanger is reduced to a minimum. - The temperature difference between the distillate and the incoming waste water is only 15 °C, which avoids overheating the rinses. - The machine works 24 hours a day and self-adjusts its flow rate according to the level of the feeding tank. When faced with little water demand, it even works with less than 50% of its nominal output. - Cleaning of the heat exchangers is fully automatic. An even more interesting feature of MKR’s technology is that the evaporators can combine the mechanical compression technology with that of thermal energy in the form of steam, which further lowers the running costs of these machines.

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FOCUS ON TECHNOLOGY

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Increasing the Load Capacity of a Cataphoretic Coating Plant’s Elevator by Around 700 kg with Limited Downtime: The Challenge Won by Verniciatura Padana Foresi and Conveyors Nord Gabriele Lazzari, ipcm®

Verniciatura Padana Foresi has been collaborating with Conveyors Nord, a leading manufacturer of conveyors for the coating industry, for almost forty years. Recently, it trusted the company once again with an ambitious project. The new elevator was successfully installed in the cataphoretic coating plant during the Christmas break: now, Verniciatura Padana Foresi can treat products weighing up to 2,500 kg.

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FOCUS ON TECHNOLOGY

erniciatura Padana Foresi began its activities in the field of

and with the required characteristics, enabling Verniciatura Padana

contract coating about forty years ago using a painting plant

Foresi to subject parts weighing up to 2,500 kg to its cataphoresis

equipped with a Conveyors Nord conveyor.

process.

Over time, it has expanded its operations and target markets and, therefore, it has revamped its powder coating and cataphoresis plants

Inherited and upgraded plants

several times.

Verniciatura Padana Foresi SRL (VPF) was founded in Verdello

It was precisely for the latter that Conveyors was again involved at

(Bergamo, Italy) in 1984 after the acquisition of coating contractor

the end of 2021: Verniciatura Padana Foresi wanted to increase the

Verniciatura d’Adda (Canonica d’Adda, Italy), initially specialised in

capacity of the elevator in its tank by around 700 kg in order to further

anaphoresis coating and later converted to cataphoresis.

differentiate its production – a strategy that has enabled it to grow over

With this operation, Verniciatura Padana Foresi inherited the Verdello

the years and achieve its current turnover.

factory and its plants, which it then expanded and revamped to meet

However, this was not an easy task, because it was necessary to install

the new market demands. Its automated, remote-controlled plants

the elevator in an already existing, very compact system and adapt it

are now divided into two buildings and serve a variety of sectors:

to the conveyor, completing the whole project during the Christmas

automotive and commercial vehicles, agricultural and construction

holidays’ production shut down. After an initial analysis of the project’s

machinery, train components, small metal parts, household

feasibility, Conveyors manufactured and delivered the conveyor on time

appliances, interior design, and heating systems.

The new elevator installed at Verniciatura Padana Foresi (opening photo) and frames loaded with workpieces at the entrance to the pre-treatment tunnel.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

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The Verdello plant, which takes up 20,000 m2 (7,100 of which are covered), is equipped with two powder coating systems, whereas the Verdellino one takes up 17,000 m2 (9,000 of which are covered) and it is devoted exclusively to cataphoresis treatments. Although the company had initially chosen to specialise in the cataphoretic coating technology because it is better suited to automotive parts, which account for a large part of its workflow, it has since diversified both its services and target sectors. “We do not have an individual core business now, but rather we have differentiated our activity so that we can remain competitive in the market. Upon customer request, we even offer further services such as sealing, riveting, and other customised treatments, as well as packaging, © ipcm

Giancarlo Quistini from Verniciatura Padana Foresi (left) and Giovanni Majer from Conveyors Nord. Above, the old elevator.

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storage, transport, and technical support with highly qualified technicians who can provide methodical, preventive, and scheduled assistance,” says Giancarlo Quistini, the owner of Verniciatura Padana Foresi.

FOCUS ON TECHNOLOGY

Efficient and reliable

With Conveyors Nord since even before VPF’s foundation The differentiation of the services offered and the markets covered, together with the spread and evolution of the cataphoresis process, have changed Verniciatura Padana Foresi’s requirements over the years, leading it to update its equipment several times. The powder coating systems were renovated

solutions for surface coating since 1988.

already at the beginning of the century. The cataphoresis one had its conveyor replaced in 1996, a new drying oven with a larger capacity (from 5 to 11 load bars) installed in 2011, and a chemical spray pre-treatment tunnel integrated in 2015. The constant factor has been the collaboration with Conveyors Nord S.r.l., which supplied the original conveyor in 1978 (inherited by the company after the acquisition of Verniciatura d’Adda) and upgraded it in 1996. Finally, striving to further expand its services, VPF turned to Conveyors once again in winter 2021 for the installation of an elevator that would allow it to increase the weight (and therefore expand the types) of parts to be treated in its cataphoresis tank, by raising the system’s load capacity by almost 700 kg.

electrostatic systems for liquid painting

The numerous challenges faced by the new elevator “We faced multiple challenges during the analysis and installation

electrostatic systems and spraying booths for powder coating

phases. Over the years, the plant had undergone a number of changes to adapt it to new production requirements and regulations, but the components that did not require any modification had been retained. Therefore, we had to adapt and

pneumatic systems for high-, medium-, and low-pressure painting

install the elevator in an already existing, very compact system and make it compatible with the original conveyor’s trolleys – all of this at Christmas time, when the company’s operations were suspended. Consequently, in order to reduce the installation and

IR and UV drying systems

commissioning time, the elevator was assembled and pre-wired in our factory, partially disassembled, and then transported to VPF’s Verdellino plant,” explains Giovanni Majer from Conveyors Nord. “Initially I did not think this was possible, but we worked out the

robot and reciprocators

best solution together with Conveyors’ technicians and we started production again with only one and a half days delay compared to the planned resumption of operations after the Christmas break,” notes Quistini.

Features and functions of the elevator • Vertical stroke: 2,450 millimetres • Immersion and elevation speed: approx. 4.1 metres per minute, controlled by an inverter • Moving track length: 4.6 metres

www.cmspray.it

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• Maximum load capacity: 2,500 kilograms

CM SPRAY s.r.l.

SPECIAL ISSUE - PaintExpo

The automated plant now consists of a conveyor that moves the

reducing the film density and the drying temperature, while at the

parts along an eight-stage multi-metal chemical spray pre-treatment

same time guaranteeing effective paint transfer and high chemical

tunnel, performing bicationic phosphating and pickling to minimise

and corrosion resistance. Verniciatura Padana Foresi wanted to make

the impact of the oxide released on the substrate by the laser

greater use of this system, even for products with higher volumes:

engraving process.

thanks to its new Conveyors elevator, it can now pick up components

The last stage is that of passivation with a Chemetall nanotechnology

weighing up to 2,500 kilograms from the conveyor, immerse them in

product to increase salt spray resistance. Afterwards, the parts

the tank, and raise them back. In order to immerse the load bars in

are transported to the automated cataphoresis tank (4.5 x 1.7 x

the cataphoresis tank while preventing dirt from accumulating on the

2 metres) for the application of a black epoxy primer that allows

elevator’s tracks, these are placed externally, above the booth and

The cataphoresis tank.

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The new elevator.

FOCUS ON TECHNOLOGY

not inside it. In addition, in order to facilitate

the operators and enable them to carry out maintenance activities in total safety, a structure with walkways, ladders, and railings was built to provide access to the driving elements, the steering mechanism, and the lifting chains. Afterwards, the parts are rinsed with ultrafiltrate, i.e. the solution extracted from the closed-loop tank itself, and finally dried in an oven. They are then finished and prepared to be packaged and finally shipped to the company’s numerous customers throughout Italy.

The frames are completely immersed in the cataphoresis tank.

YOUR SYSTEM SUPPLIER FOR INDUSTRIAL COATINGS is looking forward to meeting you at Paint Expo!

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A long-standing but future-oriented collaboration “The collaboration with Conveyors has been going on for almost forty years and it has always been synonymous with success for Verniciatura Padana Foresi,” explains Quistini. In fact, the company has greatly improved its production after each plant upgrade. It currently employs over one hundred people, serving mainly local customers – due to strategic reasons and in order to optimise transport costs – but also businesses from all over the country, which rely on VPF for its quality standards and the wide range of services it offers. “Once again, Conveyors’ technicians have confirmed their willingness, professionalism, and attention to detail. We are extremely satisfied with the capabilities of the new elevator and we will keep on relying on them for any further revamps of our systems in future,” states Quistini. The elevation phase after the cataphoretic treatment and the touch screen with the plant’s synoptic panel.

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PIROMAX Where effectiveness meets gentleness. With PIROMAX ovens thermal paint-stripping is performed only through heat, paint is incinerated without altering the piece dimensionally or mechanically.

ciroldi@ciroldi.it

+39 059 386012

eosmarketing.it

ciroldi.it

FOCUS ON TECHNOLOGY

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Autec Focussed on Decarbonisation and Chose Hybrid Polymerisation Ovens for its New Coating Plant Monica Fumagalli, ipcm®

After the decision to relocate production to France, Autec, a leading manufacturer of snow removal and urban cleaning equipment and vehicles, has invested in an advanced factory project where innovation and environmental sustainability have paved the way for optimising consumption. The choice of hybrid (gas and electric) polymerisation ovens for its new coating plant has played a decisive role in this respect.

One of the snowploughs manufactured by Autec.

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FOCUS ON TECHNOLOGY

General view of the paint shop with the overhead conveyor by Industrie-Systèmes.

he process of reducing CO2 emissions, known as

new baking solution has been Autec (Aurillac, France), a producer of

decarbonisation, is one of the most strategically important

equipment and road vehicles for snow removal and urban cleaning

objectives in the manufacturing industry, firstly in terms of ethical

since 1992. This company has recently made headlines for setting up a

and environmentally friendly corporate policies and secondly in terms

new production site in the heart of the agricultural region of Occitanie,

of savings. This is why resource hybridisation, i.e. the combination of

where it has decided to relocate production, previously carried out

energy from different sources, has been playing an important role in

in Eastern Europe. With this reshoring operation, supported by the

an increasing number of production systems, not least in paint shops,

national and regional governments, the well-known French firm is

for some time now. Indeed, surface treatments are known to be one of

aiming at creating new jobs and handling a volume of raw materials

the most energy-intensive operations and polymerisation, in particular,

amounting to 700 tonnes.

is one of the phases that have the greatest impact on a company’s energy costs.

Relocation as an opportunity for innovation

Industrie-Systèmes since 2010 has been working with Eurotherm Spa,

“We have been building and distributing vehicles useful to communities

an Italian firm specialising in the design, manufacture, and installation

for thirty years now,” says Mr. Cavanie, production manager at Autec.

of liquid and powder coating lines, to distribute its equipment on

“We follow the construction of our vehicles from A to Z, studying every

the french market. It has developed a polymerisation solution that

part in detail, including heat engines and any electrical and hydraulic

combines the two most common oven heating systems, namely gas

components. This is one of the reasons why our customers choose

and electric, into one device. One of the first companies to test this

us, why our turnover is constantly growing – with a forecast for 2022

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

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The coating system installed by Industrie-Systèmes - Eurotherm Spa and the Cogeim shot blasting machine.

of around 8 million Euros – and why we are the industry leader in

Italian company Cogeim, a 3-stage pre-treatment plant, two powder

France with a 60% market share. We decided to relocate production

and one liquid coating booths, two hybrid polymerisation ovens, and

with a view to development in one of the most promising areas in

a final storage buffer for drying the components. “We were looking

terms of both resources and market penetration, in order to have

for a plant solution that met the two key requirements of our new

greater control over our workflow and our vehicles’ performance

factory: innovation and sustainability,” indicates Cavanie. “We therefore

level, but also because it allows greater independence in managing

turned to Industrie-Systèmes - Eurotherm Spa because it is a plant

processing phases. At Autec, we also believe that innovation must be

engineering firm known in France for the quality of its work, particularly

combined with sustainable production: these two elements can and

in the powder coating field, and for its consultancy service, which

must go hand in hand, and a company like ours cannot overlook them

supports customers from the preliminary design phase to the coating

nowadays. In fact, one of the objectives we have set ourselves in our

of the first workpieces, not to mention the high technical expertise of

development plan concerns the decarbonisation of our factory with

its team. A visit to Eurotherm Spa’s Italian factory confirmed Autec’s

the integration of the most advanced production systems that the

choice. We mainly required an effective, flexible and, above all, energy-

market has to offer.” The relocation plan was launched in 2021 and the

efficient system: Industrie-Systèmes offered an innovative solution

new production site began operations in March this year. The project

for our plant’s two polymerisation ovens, which are among the most

included laser and plasma cutting, robotic bending, assembly, and

energy-consuming devices in our paint shop.”

liquid and powder coating departments.

“Savoir faire” in coating

A convincing hybrid system “The type of oven that we offered to Autec,” explains Mathieu Breton,

The new coating line consists of an overhead conveyor loaded through

the general manager of Industrie-Systèmes, “is based on a very simple

an automatic elevator and unloaded manually, which takes the parts

principle, that of hybridisation of gas and electricity energy sources.

through a manual and automatic shot blasting cabinet supplied by

Eurotherm Spa created it starting from its standard oven equipped

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FOCUS ON TECHNOLOGY

 

The outside of the shot blasting system.

with a Riello RS 28 air vein methane gas burner, with a maximum power of 360 kW, and adding a 120 kW electric battery with a static relay modulation system. The oven is brought to the pre-set temperature of 200 °C using the burner’s power alone. Once the desired temperature has been reached, the burner is switched off and the electric batteries are switched on to maintain it. In this way, consumption of methane gas is only required to reach the right temperature, while its maintenance is guaranteed by the electricity provided by the photovoltaic panels installed by Autec.” “Integrating electricity as an energy source for oven operation,” confirms Cavanie, “has been an enormous advantage in terms of consumption and it has enabled us not only to reduce one of our highest budget items, but also to reduce the environmental impact of our processes and create a healthier environment for our operators. As said, these aspects were actually among the objectives of the investment made in our new paint shop





SPECIAL ISSUE - PaintExpo

in particular and in our entire factory in general.”

Decarbonisation, Autec’s next objective “Sustainability was one of the cornerstones of our reshoring project from the outset,” concludes Cavanie “With a view to our total decarbonisation and zero emissions goals, the hybrid solution offered to us by Industrie-Systèmes and Eurotherm Spa convinced us straight away. There is still room for improvement, but our new factory and the business support promoted by the French government and by our region have enabled us to take a major step forward in this direction. Thanks to our new painting © Industrie-Systèmes

system, we have also improved the quality of our coatings and, therefore, of our vehicles, which are subjected to heavy wear and tear, reduced lead times, and increased production volumes, while optimising flexibility in terms of part size and colours to be applied. Last but not least, we have improved safety and ergonomics to the benefit of our operators. When innovation goes hand in hand with sustainability, it truly shows.”

Workpieces hung inside the shot blasting machine.

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The two hybrid polymerisation ovens installed by Industrie-Systèmes Eurotherm Spa with the coating booths.

FASTRIP S, vertical spray system for the chemical stripping of metals The Fastrip range has always stood out for its versatility. That is why Fastrip S, a vertical spray system designed to optimise the working spaces beside the pre-existing paint stripping lines, was born. Thanks to its modular design Fastrip S meets the needs of the industry, allowing to modify the size of the machine according to the working spaces available. The system is designed for high temperature stripping processes (up to 150°). Thanks to the variable design of the piece holding baskets, it is able to strip paint from pieces of different shapes and dimension, made by light alloys or ferrous alloys.

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4.0

SUCCESS STORIES

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Helping the Customer with Expertise Surface technology and powder coating are complex subjects. When companies switch from wet painting to powder, they often lack the specific knowledge to successfully handle special tasks in their daily operations. Thanks to intensive cooperation and expert knowledge, practical experience as well as the broad portfolio of a powder coating manufacturer, a sheet metal processor in Germany has achieved rapid and sustainable success with powder coating. © KABE

teland Apparatebau GmbH & Co. KG in Rommerskirchen (Germany) is a sheet metal processor with a very high level of vertical integration. Already in its fourth generation, the

family-owned company offers comprehensive services for a wide range of customers, from design to sheet cutting, machining, welding, coating, labelling and assembly. Some time ago it was decided to switch from wet paint coating to powder coating. Although the new coating plant was operating satisfactorily, a number of ongoing projects offered room for optimization. This was mainly due to the lack of skilled personnel who would be able to bring the necessary expertise into the company from outside. For this reason, they contacted the experts from the powder coating manufacturer KABE.

Small batch sizes with large variance As a classic in-house coating company, Steland has to constantly coat new parts and materials with a wide variety of characteristics. In addition, there are special requirements and specifications from the customers as well as a wide variety of batch sizes. Bastian Dreyer, regional sales manager at KABE Pulverlack Deutschland GmbH, as the former head of a powder coating business, can understand this problem: “Today, a great deal of knowledge is required at various levels in powder-coating operations, which is often not available in the company’s technical background. The reasons for this are the lack of skilled workers and the increasing complexity of the subject area. In such cases, we come into play as a specialist partner. KABE Pulverlack can offer customers targeted solutions with their knowledge of a wide variety of projects and thanks to many years of practical experience. In addition, with our modern and versatile technical center and the hands-on experts working there, we are able to develop customerspecific solutions quickly and efficiently.”

Solutions from an existing powder coating repertoire Steland Apparatebau GmbH & Co. KG is a sheet metal manufacturer that offers comprehensive services from design to sheet cutting, machining, welding, coating, labelling and assembly.

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Steland was commissioned to manufacture 19-inch bays and enclosures for a new server rack technology. The specification for the powder coating was to apply a black fine-structure powder,

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

which would then be printed on. The first powder coating used had a structure that prevented high-quality pad printing. In addition, the manual handling of the parts repeatedly caused scores on the surface. This required wearing gloves during the packaging process, which was unpleasant for employees. Steland described the problem to Bastian Dreyer of KABE Pulverlack. In close cooperation between the product managers at Steland and the KABE technicians in Switzerland, a suitable mixed powder with a fine, silky-matt structure was evaluated from the broad repertoire available. Small adjustments to the formulation made this powder ideal for printing on and the handling could subsequently take place without gloves. The end customer was also convinced by the KABE powder and changed the specification of its products. “These types of practical problems and the identification of solutions in direct cooperation with customers are constantly expanding KABE’s knowledge base. This enables us to quickly help other customers with similar challenges,” says Bastian Dreyer. Another well-known challenge is to achieve good coverage with critical colors such as RAL 2004 (pure orange). For a heating manufacturer, Steland produces products with square tubes, which are very dark

Steland was commissioned to manufacture 19-inch bays and enclosures for a new server rack technology.

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SUCCESS STORIES

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KABE technicians provided Steland with a suitable mixed powder with a fine, silky-matt structure. The close cooperation between Steland and KABE resulted in a precisely coordinated combination of powder coating and ink, which now also meets the most stringent requirements.

due to the manufacturing process. Because using a primer was not

it also had to be possible to print on the material. KABE knew that the

possible for design and economic reasons, the powder coating had

powder coating they offered guarantees chemical resistance. But at the

to be applied with around 120 µ thickness. This resulted in a long

same time achieving a good gloss level and good application so that the

application time, excessive material consumption and an orange peel

parts could be printed with pad printing required the formulation to be

and pin-hole appearance on the end product. So Steland had a lot of

adapted. KABE provided sample powder, adapted the formulation and

coating problems to solve.

carried out tests together with the customer and the ink manufacturer.

Bastian Dreyer of KABE knew that a carton of RAL 2004 powder left

This close cooperation resulted in a precisely coordinated combination

over from another project could be the solution at Steland. Even

of powder coating and ink, which now also meets the most stringent

during the first test coating on site, both the layer thickness and the

requirements.

coating time were halved and at the same time the surface quality

“KABE thinks holistically for the customer and always thinks out of

was sustainably improved. “A coating powder from KABE’s range of

the box. In conjunction with our practical experience, we can develop

products was the solution to our issue and we did not need to develop

the best solutions for our customers. At the same time, thanks to the

a special powder. This knowledge can only be gained from practical

challenges our customers bring to us, we are constantly expanding our

experience and in conjunction with experienced experts,”

expertise and portfolio”, explains Bastian Dreyer.

Mr. Ralf Steland, Managing Director at Steland Apparatebau states with

Steland completely got rid of wet painting and today only applies

conviction.

powder coatings. “From my experience with KABE, the close

Customer-specific solutions

cooperation, the service and the advice given stand out. In case of problems, we can call and get information, samples or active support

Nevertheless, KABE was already able to develop customer-specific

on site quickly. What KABE Farben offers us in terms of service is really

solutions for Steland. For example, as part of a new project for white-

excellent,” concludes Mr. Steland with satisfaction.

coated fittings from a large sanitary system manufacturer, which places very high demands on chemical resistance. At the same time,

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For further information: www.kabe-farben.ch

The new electrostatic Rotary Bell Atomizer

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FOCUS ON TECHNOLOGY

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Welcome in the Rubber Valley: 20 Rotamat Coaters Within a Radius of 10 Kilometres Frank Siegel Walther Trowal GmbH – Haan, Germany

f.siegel@walther-trowal.de

Around the Lago d‘Iseo in Northern Italy so many companies are producing components from elastomers that insiders call the region around the lake the “rubber valley” of Italy. Once they have been produced, many of these components receive a coating consisting of an anti-adhesion lacquer, decorative paint or primer. Therefore, it is not surprising that within a radius of 10 km the lake region contains the globally largest accumulation of Rotamat coaters from Walther Trowal. © Interseals

ontrary to lake Como or lake Garda, the Lago d‘Iseo is not very well known, even in Italy. Water sports fans know it as the location of the legendary motor boat yard

Riva. And a few years ago, the lake became temporarily famous, when Christo and Jeanne-Claude installed the yellow-golden “floating piers” at its shore. Even less known is the fact that the lake shore is also home to Italy’s rubber industry. In villages like Paratico, Sarnico and Villongo about 200 companies are producing elastomer components for the automobile, aerospace and furniture industry. Even parts for the world of fashion are made there. Each year the companies in this area make and ship components worth several billion Euros: there is a reason why this region is called the “rubber valley” of Italy. Many billions of small parts, such as O-rings, seals for machines and vehicles, zippers for the textile industry and furniture fittings, must be coated with anti-friction lacquers, primers or decorative paint. Therefore, it is not surprising that this region produced many coating job shops. Especially those companies with customers in the automobile and aerospace industry, who demand high process stability and consistent results, have been using Rotamat coaters for quite some time: within a radius of 10 kilometres 17 Rotamat coaters are currently operating. This makes the Lago d’Iseo the region with the, globally, largest concentration of Rotamat coaters from Walther Trowal. In addition, two machines are at the Lago Maggiore, and one is in Treviso, about 50 km from the Lago d’Iseo.

Among other products Interseals produces O-rings made from elastomers.

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FOCUS ON TECHNOLOGY

At its plant in Capriolo Interseals operates four Rotamat coaters. At Pol-Technology in Poland another three units are installed.

Interseals: seven Rotamat coaters within the same group of companies

from a hardware store and the nozzle from a garden hose are fully

The first coating job shop utilizing the Rotamat coating technology was

coatings, consistency of the coating results and audits, we must have the

Interseals in Capriolo. The company produces O-rings and specially

process safety of the Rotamat coater.”

formed components made from elastomers. In addition, the company

sufficient. However, when it comes to high-value two-component

operation also coats the products of other manufacturers. Among

The world’s centre for coating of mass-produced small parts

other things Interseals has also specialized in coating technologies with

Whoever wants to get a complete overview over the application

multi-component lacquers. The first machine for drum coating of small

possibilities of the Rotamat systems and wants to see the coaters in

components with an anti-friction lacquer was commissioned in 2009.

everyday operations, should travel to the Lago d’Iseo: all users are

Today Interseals in Capriolo works with three R 90 Rotamat coaters

practically a stone’s throw apart from each other.

(processing capacity of up to 50 l) and a R 90C (processing capacity of

For coating applications with anti-friction lacquer for O-rings, seals and

up to 75 l) with a drum diameter of 800 / 850 mm, for batch weights

other components alone the visitors can inspect 12 Rotamat units. Just a

of about 50 / 100 kg and a processing volume of 50 / 75 l. At the

few steps away two machines are used for the application of decorative

subsidiary company Pol-Technology, founded in 2016 and located near

coatings on metal components for the fashion industry. And a little

Kattowitz in Poland, initially 2 Rotamat coaters were installed, and in

further away several Rotamat units are coating plastic components for

2017 a third machine was commissioned. On average, each Rotamat

the furniture industry with water and solvent based decorative and

machine coats nearly 40 million parts per year with water-based

functional materials for products like handles and other fittings. Two

lacquers.

additional Rotamat systems are utilized for coating connecting elements

Dieter Adamkiewicz, the co-founder and until 2019 one of the general

for the aerospace industry, including safety components. These

managers at Interseals, explains: “When a task simply consists of

products require the highest degree of process safety and consistency

coating an assembly component with a bit of Teflon, a concrete mixer

of coating results.

is not only coating its own products, but within its coating job shop

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

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The automatic spray guns are evenly applying the coating material on the surface of the elastomer components.

A detail of the touch screen.

The Rotamat technology today

the R 60 the company responded to numerous market demands: many

The first machine, commissioned by Interseals 13 years ago, is still

coating job shop customers are producing smaller and more compact

running without any problems. However, in the meantime a lot of

machine components, for example, motors and pumps, which generate

innovative features were integrated into the Rotamat technology. With

the same performance as the larger products. Accordingly, the seals for

new spraying systems, precise dosing of the material flow, intuitive

these devices are becoming smaller. Today the volume of 50,000 O-rings

operating panels and the integration of the machine controls into the

with an inner diameter of 3 mm and a cord thickness of 1 mm amounts

higher level computer systems of the users, Walther Trowal has adapted

to only 0.5 l.

the machines to the latest customer requirements.

However, since the coating process requires a certain minimum fill

New spray guns are evenly distributing the coating material on the

quantity, Rotamat machines with smaller drums became an urgent

surface of the elastomer components. At the same time, the precise

necessity. For this reason, Walther Trowal developed the Rotamat model

control of the material flow ensures that the thickness of the material

R 60 with a fill volume of only 15 l but with the same technical and

layer is exactly within the specified values. Therefore, the Rotamat

performance features of its “larger siblings”. The R 60 is ideal for coating

coaters are especially suited for components with complex, delicate

small product batches. But it can also be used for the sample coating of

shapes and for tasks, where process safety and consistency of results

larger components.

are essential. Examples are two-component coatings with lacquers

Moreover, Walther Trowal has opened access to the digital world of the

containing pigments or the coating with solvent-based materials that

customers: a communication processor allows the integration of the

must comply with special technical requirements.

Rotamat systems into the controls of the entire manufacturing process.

For example, the dosing of the material flow is controlled with a precision of one tenth of a gram per minute. This guarantees that

With a startup into the future

the coating process is always utilizing the prescribed lacquer quantity

The C.S.I. Centro Servizio Industriali, founded in 2021 and also located

and that the required coating thickness is precisely and consistently

at the lake in Paratico, pursues an entirely new approach. The company

achieved. With this new technology the coating process is now

is not only a manufacturer but also does R&D and provides consulting

managed by exactly measured, actual data. This helps the customers,

services. The focus is on three technologies:

among other things, with audits: they can reliably prove that their

• the cryogenic deburring of, especially, small components

production process takes place with a high degree of process safety and

• the drum coating with anti-friction lacquers

consistency.

• the coating with plasma and parylene systems.

Walther Trowal has also continuously improved its machine range. With

The company is utilizing two Rotamat coaters and will shortly

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FOCUS ON TECHNOLOGY

commission a third unit. CSI uses its experience as coating job shop to advise companies in the region hands-on directly at the machines. Stefano Ferrari, the founder and general manager C.S.I. explains: “Numerous job shops were founded in the 1980’s. But many experienced specialists are now retiring. This leads to a sizable loss of know-how. For this reason, we offer training courses. Many users are surprised to learn about the technical versatility of the Rotamat coaters. In addition, we are intensively working on new technologies.” C.S.I. operates a test lab with sophisticated equipment that allows comprehensive studies for the company’s customers. This allows the companies in the lake region to demonstrate to their customers what excellent coating qualities they can produce. An important part of the work at C.S.I. is to support companies working for customers from the automobile, aerospace and medical engineering industries in the preparation of complete documentations covering process safety and consistency of the coating results. In addition to its own production and the analytical services in its internal lab C.S.I. is also studying new materials. One important research

Filter cabinet can be equipped with disconnect options.

project deals with solid lubricants with anti-microbial or bacteria resistant characteristics.

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coolant, washer chemicals & mobility enhancer, waste water treatment chemicals, Zero Liquid Discharge plants, state of the art chemical controllers.

MST CHEMICALS s.r.l. - Via Primo Maggio, 31 - San Zenone al Lambro (MI) - Italy - Tel. +39 02 98264351 - sales@mstchemicals.com

SPECIAL ISSUE - PaintExpo

The Rotamat technology in more detail

During the entire coating process pre-heated, turbulence-free air

The Rotamat systems for coating mass produced small parts are

is guided into the rotating drum to heat the parts to the specified

utilizing the hot drum technology, whereby the parts are coated in a

temperature. The work piece temperature is directly and continuously

closed rotating drum with one or more automatic spray guns. It allows

measured with an IR sensor. A PID controller sets the temperature

the coating of all kinds of components made from plastic, such as

depending on the work piece temperature. At the same time, it takes

elastomers, ABS, PC, PS, etc., as well as components made from metal or

into account the actual air flow. Because of its high efficiency, the

wood. Coating materials can be water and solvent based lacquers.

machines require a relatively low power input of a few kW’s.

The parts must no longer be placed on special racks but are loaded into

Upon completion of the coating process the work pieces are unloaded

the drum of the Rotamat system as relatively large work piece batches.

by mechanically tilting the drum downwards. Post drying, for example,

One or two automatic spray guns apply the coating material evenly on

in a special oven, is no longer necessary. The parts are discharged from

the surface of the parts, which are continuously tumbling over each

the drum completely dry and can be immediately processed in the next

other.

manufacturing stage.

The new R 60 Rotamat system can also handle work piece volumes of under 15 l.

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LEADING EVOLUTION SINCE...

ALWAYS!

Manufacturers of all sizes are benefiting from automation. Complete your automated paint line with spray guns and mixing systems that easily integrate with robots and reciprocators. Thanks to Automation you can:

Lower operating costs by reducing material waste by up to 30 percent

Reduce labour costs while dramatically improving quality

Protect employees from dangerous conditions and repetitive tasks

W W W. G R A C O . C O M / A U T O M AT I O N

Achieve higher transfer efficiency

BRAND-NEW

Axalta Coating Systems Presents at PaintExpo 2022 in Karlsruhe: “Your Passion, our Coatings”, Innovative Products and Services Axalta Coatings Systems will showcase its latest liquid, electro-deposition and powder coating solutions at the international trade fair PaintExpo.

t PaintExpo 2022, Axalta will be presenting current

preparing for a very wide range of customer requirements. Axalta’s

developments in a full range of coating technologies. Featuring

coating solutions are used throughout the world in the transport

a portfolio of forward looking and state of the art liquid,

sector, including the automotive and commercial vehicle industry, in

electro-deposition and powder coatings alongside a modern range

numerous areas of general industry, the construction sector and for

of colour services and comprehensive advice, users will benefit

applications in architecture and interior design.

from synergies in technology. This will make an ideal contribution to

One area of the exhibition will highlight corrosion protection, to

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SPECIAL ISSUE - PaintExpo

support with the daily challenge of finding a sustainable and cost-effective solution for protecting metal substrates. Axalta is presenting a wide range of liquid, electro-deposition and powder coatings suitable for single and multi-layer coating finishes,

Industrial Equipment SURFACE TREATMENT

such as the multi-functional primer Alesta® ZeroZinc Uniprime and the E-Coat AquaEC3500, which meet the most demanding corrosion protection requirements. The ProductSelector will also be highlighted, a newly developed internet-based tool from Axalta guides customers to find the best coating system by applying certain criteria, such as climate zones and substrate. Axalta’s liquid paint system, PercoTop®, offers a genuine multitalent product for industrial finishes. Regardless of whether metals, plastics or galvanized surfaces are to be painted, PercoTop® is

SHOT BLASTING BOOTHS

suitable to coat almost all industrial substrates. This adaptability is attributable to an innovative paint mixing and

LIQUID PAINT

binding system. It is also capable of providing practically any paint colour in the desired quality and quantity in the shortest possible time. Delivery is made within two to three working days to almost anywhere in Europe meaning the customer does not require a large inventory of paints in own warehouse.

BOOTHS

The batch-to-batch colour accuracy of PercoTop® is on an outstanding high level. PercoTop® paints can be applied with any common industrial coating application technology. A comprehensive portfolio of powder coatings will also be on display at the Axalta Coating Systems stand. The wide range of different collections includes an inspiring selection of colours and effects with an almost unlimited freedom in design. Very high sustainability and good shelf life give powder paints a competitive edge. This makes them ideal for architectural applications, both indoors and outdoors, in which paint is not simply a question of colour. The ColourService range for powder paints in architecture is presented by themes such as COLOURit, ColourSelector and

POWDER PAINT BOOTHS

customized Colourwalls. To arouse a passion for paints, Axalta has developed the “Colour Experience Room” concept and introduced it into various sites in Europe. The comprehensive range of products and services will be presented live to exhibition stand visitors several times a day in an extraordinary format, with additional time for questions. “Your Passion, our Coatings”: Axalta will exhibit at Stand 3240 in Hall 3. For further information: www.axalta.com

OVENS BAKING TUNNELS OMIA - ZI n°3, 66 avenue Maryse Bastié, BP 9061 6 1 6340 L'ISLE D'ESPAGNAC France // international@omia.fr Tel. +33 6 71 52 32 09 // www.omia.de

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

Chemtec’s Offer in the Post-Pandemic Scenario Carlo Guidetti Chemtec Srl, Corbetta (Milan, Italy)

c.guidetti@chemtec.it

Reducing consumption from pre-treatment to coating while improving processes: this is the solution offered by Chemtec to face the current economic scenario among inflation, energy crisis, and post-pandemic recovery.

he economic crises of 2008 and 2012 taught the European and

• reducing energy consumption linked to exploding electricity and gas

international manufacturing industry the importance of the

costs;

equation “crisis = opportunity”. In the current economic and social

• reducing water consumption linked to global warming and a dry winter;

context of gradual post-Covid-19 pandemic recovery, we believe that its

becoming independent from raw materials subject to economic

value should be relaunched and reminded to all companies, specifically

speculation;

those operating in the industrial coating field. Whereas in 2021 the post-

• elimination of heavy metals from industrial processes, to reduce the

Covid-19 economic recovery caused excitement and significant growth

environmental impact of operations and of finished goods when they

in production in almost every sector, in 2022 things have unfortunately

have to be disposed of;

changed: general inflation and rising raw material costs are challenging

• eliminating or reducing the creation of waste to be disposed of, which

the paint industry yet again.

should instead be reused in the context of the circular economy.

The current needs of coating companies

The processes of preparing (washing, cleaning, pre-treating) metal surfaces prior to coating are heavily influenced by the current situation,

The following is a summary of the requirements and needs that are most

because they use enormous amounts of energy and water, they are

relevant to the paint industry nowadays:

dependent on speculative raw materials, they use heavy metals (zinc,

A one-chamber cleaning tunnel with TORAN 3.

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HIGHLIGHT OF THE MONTH

The entrance to the pre-treatment tunnel of F.lli Gionchetti, with PRONORTEC®.

Ethimo components waiting to be treated with PRONORTEC®.

chromium, nickel), and they create huge quantities of waste to be

no sludge or waste, uses no water, and never requires the product to

disposed of. Now more than ever, therefore, should change – understood

be replaced. It is easy to see why companies choosing TORAN 3 are able

as the possibility to exploit new innovative technologies – be considered

to eliminate the typical problems of phospho-degreasing, thus reducing

as a great opportunity.

their energy and water consumption to zero and eliminating any disposal

Chemtec’s offer

issue. TORAN 3 works on any non-oxidised metal by degreasing it and converting its surface through the formation of a nanometric protective

Phosphating is an industrial process researched and developed during

coating, which guarantees excellent adhesion of any (liquid or powder)

the first decades of the 20th century, which is still widely used in the

paint and a higher corrosion resistance degree than phospho-degreasing.

industry, both in its simplified version (amorphous phosphating or

The various companies in Italy that have chosen to replace phospho-

phospho-degreasing) and in its higher performing version in terms

degreasing with TORAN 3 include Omet (Lecco), Car Segnaletica

of corrosion resistance (tricationic phosphating or microcrystalline

(Benevento), Anderlini Meccanica (Bologna), and a number of coating

phosphating with zinc salts). These operations use huge volumes of water

contractors such as Corallo (Pordenone), Metalcolor (Pesaro), Citysi (Bari),

and energy and they create sludge (which is toxic, in the case of zinc

Cavalca (Reggio Emilia), and Ecover (Pesaro). In Europe, this technology

phosphating), as well as huge quantities of exhaust solutions that have to

has been implemented by Powell and Jaguar Land Rover (UK) and Sic and

be disposed of.

Franciaflex (France) among others, and overseas by the Legrand Group

The R&D activity carried out in the laboratory of Chemtec, a company

and Dmg Mori.

specialising in the formulation, production, and distribution of chemical pre-treatment solutions, has led to the development of two

2.Replacement of zinc, tricationic, and microcrystalline phosphating

technologically innovative products to replace them.

processes. For many years now, several processes have been on the market as

1.Replacement of phospho-degreasing and amorphous phosphating

alternatives to microcrystalline phosphating. The best performing ones

processes.

are those based on polysiloxanes or organic silanes; however, only in

TORAN 3 is a one-stage process that occurs at room temperature, creates

certain cases and with very complicated bath management do they

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139

SPECIAL ISSUE - PaintExpo

guarantee corrosion resistance levels comparable to that of heavy metal-

management of water-veil booths.

based phosphating. After more than two years of R&D work, Chemtec

Chemtec has also strived to replace conventional recycling demineralisers

has launched a new pre-treatment process called PRONORTEC , the

in cleaning tunnels. These are not easy to manage and they require

only process available on the market based on organic phosphorus

frequent regeneration (resulting in large volumes of acid and alkaline

compounds. Its particular chemical nature allows a nanometric coating

effluent). Therefore, Chemtec designs, assembles, and installs last

(30-50 nanometres) to be formed that is totally hydrophobic and hyper-

generation osmosis units that, in many cases and with small changes to

reactive with both the metal surface and the paint. The results are very

the tunnels’ hydraulic systems, allow sending very pure water to the final

interesting: in many cases, the corrosion resistance degree achieved is

rinsing stages without having to operate demineralisers.

equal to or better than that of microcrystalline phosphating (on carbon

Companies that have chosen Chemtec as their water treatment partner

steel) or chromating (on aluminium). PRONORTEC can be applied to

include GE Avio, OZ racing, Polplastic, Galdram, Cameron, Glosstech, and

any metal that has been degreased, deoxidised, and wetted with purified

Gmp in Italy; Hella in Slovenia; Amada, Faurecia, and Manitowoc in France;

water.

and Luxottica in almost all production sites.

Companies that are using this new, innovative technology include Ethimo, F.lli Gionchetti, VIV, Alsil, and Freud in Italy, the Atlantic group in the USA,

Conclusions

and Sud Ouest Laquage in France.

Technological innovation has never been as important for the paint

Finally, Chemtec’s laboratory has also simplified waste water management

industry as it is now. New developments can bring great benefits to

processes. For many years, industries have been accustomed to storing

companies that embrace change, helping them overcome most of the

waste water generated by different operations and having it collected

difficulties created by the current international economic and political

by companies specialising in its treatment. Chemtec has designed and

environment. Businesses that are able to innovate, replacing 20th century

installed several purification systems (chemical-physical reactors, special

processes with new technologies, will achieve immediate economic,

filters) to treat waste water for re-use with a view to economic circularity.

financial, and technical benefits and gain a major advantage over their

In order to treat the liquid exiting coating booths, Chemtec has developed

competitors resisting change.

the latest generation of fully automated dirt separators 4.0, which, in

Thanks to its unique and innovative technologies, Chemtec is a strategic

combination with innovative chemicals, make it possible to purify booth

partner capable of supporting any company involved in industrial coating

water simply and effectively, thus streamlining the maintenance and

along this journey of innovation, change, and improvement.

A Chemtec dirt separator 4.0 in operation.

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BRAND-NEW

A New AI Process Control Co-operation for Powder Coating Lines coatmaster AG and coatingAI partnered to provide customers with a solution to manufacture a quality product while reducing materials consumption, labour costs and environmental footprint.

he manufacturer of measuring systems coatmaster AG and

“The combination of coatmaster’s Advanced Thermal Optics technology

the developer of algorithms for improved automated coating

sensors and coatingAI’s smart algorithm-driven advanced computer

process coatingAI have officially entered a strategic partnership

vision and machine learning technologies harnesses two powerful

to leverage the opportunities of artificial intelligence in order to

digital age tools to deliver real benefits for people – and the planet,”

provide even more quality, efficiency and profitability, as well as

stated Marlon Boldrini, the CEO of coatingAI.

environmental benefits, to professionals searching for the optimisation

“We are delighted to be partnering with coatingAI and look forward

of the automated powder coating line industry.

to helping customers in the automated coating line sector confront

The closed-loop control solution for automated powder coating

two major challenges – producing quality results and overcoming

processes developed by coatingAI will draw on data collected from the

the shortage of skilled labour – and both of those while ensuring

thickness measuring devices manufactured by coatmaster, that feature

continued profitability,” also added the Co-Founder & Co-CEO of

the optical sensor technology.

coatmaster AG, Prof. Dr. Nils Reinke.

This new solution will allow to automatically and intuitively control powder coating lines towards process stability, resulting not only in reduced coating material consumption and better homogeneity, but

For further information:

also in lower personnel resource requirements.

coatmaster.com and coatingai.com

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BRAND-NEW

The Availability of Preservatives is Decreasing, According To CEPE CEPE stressed the threat to the availability of preservatives, which are used to extend the useful life of coatings, inks, cleaning products and personal care items.

EPE has launched a campaign to inform about the threat to the

is leading to a reduction in the number of existing preservatives. The

availability of preservatives, which are used to extend the useful life

situation is now reaching a breaking point.” CEPE calls on regulatory

of everyday products such as coatings, inks, cleaning products and

authorities to change the requirements of the Biocidal Product Regulation

personal care items. The industry is increasingly concerned as current EU

(BPR), which governs the authorization and use of preservatives.

regulations and review processes are leading to phasing out preservatives

“The current regulations are simply not fit for purpose, and we face the

while no new alternatives become available.

very real risk of having no preservatives available for key products like

They are critical for extending the useful life of products such as water-

paints, printing inks and artists’ colours,” Davidson said. “Reports have

based paints and inks as without them microorganisms in water grow and

already shown the urgent need to revise the Biocidal Products Regulation.

damage the coating product in the can or the finished coated surface.

We need action now to make sure that manufacturers can continue to

This would lead to increased product waste and the need for more

supply existing preservatives, so that our members can continue to make

frequent repainting, directly contradicting the EU’s green and circular

properly-preserved paints and inks, while encouraging the innovation and

ambitions.

development of new preservatives for the future.”

Christel Davidson, CEO of CEPE, said: “The current regulations have created a lengthy and costly system where manufacturers of preservatives

For further information:

rarely bring new substances to the market. In addition, a review program

www.cepe.org/campaign-coatings-need-preservatives

Specialists in Internal Transport Systems; Power & Free, Monorail & Floor Conveyors Handle loads up to 5000 kg Each system custom-built to clients needs & wishes Products range from manual to fully automated systems Possiblity of turn-key installations Own maintenance and service department

Contact: +31 344 61 6363 info@railtechniek.nl

Visit:

Follow: www.railtechniek.com railtechniek-van-herwijnen-bv railtechniek

Presented at the Dürr Open House 2021: the EcoBell4 can perform colour changes in just four seconds.

INNOVATIONS: PRESENT&FUTURE

EcoBell4 Increases System Availability and Capacities Philipp Dunkel Dürr Systems AG - Bietigheim-Bissingen, Germany

philipp.dunkel@durr.com

The newest atomizer generation from Dürr can make a real contribution to improving overall equipment effectiveness (OEE) in the paint shop. The EcoBell4 performs colour changes faster than any other high-speed rotary atomizer, reduces paint and solvent consumption as well as VOC emissions, and features RFID technology for predictive maintenance. For the first time, Dürr is offering two variations in the same atomizer generation: the basic version for standard applications and the pro version for special processes like 4x1C or 3x2C.

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INNOVATIONS: PRESENT&FUTURE

he pro version of the EcoBell4 featuring the new 4-main-

needle technology is the benchmark for efficiency and resource consumption: The patented system needs just four

seconds per colour change for high-runner paints.

The significantly shorter colour changes positively impact paint and solvent losses, which are lower than any other atomizer on the market. Less waste not only cuts operating costs but is also better for the environment with fewer VOCs generated.

Universal use for all painting tasks The EcoBell4 Pro can be used for interior and exterior painting in addition to all paint materials. The portfolio includes atomizers for both water-based and solvent-based paints in. The EcoBell4 Pro can serve both existing and new painting needs, from 4x1C painting for the base coat to 3x2C solutions for clear coat and all combinations in between.

The perfect combination: EcoBell4 and EcoProBooth The flexibility and universality of the EcoBell4 Pro are best demonstrated in combination with the new EcoProBooth. With

Patented world innovation: EcoBell4 Pro with exchangeable electrode ring.

its smart painting booth design, the EcoProBooth combines all painting tasks in just one box, including the new, innovative EcoBell4 Pro Ux atomizer. The same bell disk/shaping air ring and external charge system handle all interior, exterior, and metallic painting (bell-bell process). The atomizer equally applies narrow spray jets inside the body and wide spray jets on the outer skin with Dürr’s usual high efficiency. Another innovation is the patented exchangeable external charge systems, which individually combine within the Pro series. Dirty electrode rings are simply discarded and replaced with clean ones in one of the four service cubicles of the EcoProBooth – without stopping the system for cleaning to take place.

Fault prevention with RFID technology Whether in the bell disk, the shaping air ring, the turbine or the atomizer: Dürr adds RFID technology to improve processes directly in the paint booth and maintenance. RFID (radio frequency identification) is a wireless data exchange between a transponder and a writing or reading device. Since Dürr’s transponders can read and write operating data, components can store data directly and track wear. This technology provides operators with reliable information about the current condition, enabling them to make optimum use of the service life of components and plan maintenance times in advance. However, it is not just the parts needed for the maintenance work displayed. Visualization of required work steps occurs at a maintenance station with an RFID connection in assembly videos using defined

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

145

Dürr’s latest atomizer generation can make a real contribution to improving the OEE of a paint shop.

sequences. Typical sources of error, such as the incorrect assignment

addition, Dürr has enhanced the external charge system to make it

of bell disks or air shaping rings after a break for cleaning, can also be

even more efficient. Other new features include a robust rotation

eliminated thanks to RFID.

speed acquisition system designed for easier maintenance, a

The system detects the incompatible component when it reads

vibration sensor integrated into the robot that detects imbalances in

out the data and warns the operator via a pop-up window even

the bell disk and turbine before they cause damage, and a protective

before the painting process starts. This feedback increases system

stocking with a patented attachment concept.

availability and positively affects the first-run rate.

It reduces soiling so that at least four hours of painting are possible

All EcoBell4 atomizers are equipped with RFID technology. In

without cleaning the atomizer in between.

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HOW IT’S COATED

Black Paints Save Birds Edited by Iberdrola, S.A. Bilbao – Spain

comunicacioncorporativa@iberdrola.es

Based on the findings of a Norwegian research and the experience of French airports, Iberdrola painted wind turbine blades black and applied vinyl shapes resembling eyes to protect birdlife. berdrola, one of the world’s principal energy companies, a leader

for Nature Research1, which estimates a 70% reduction in the number

in renewables, and it is spearheading the energy transition towards

of birds spotted after applying this measure. The solution creates more

a low-emission economy, supplies energy to around 100 million

contrast between the blades and makes them easier for birds to see.

people in dozens of countries and has renewable, grid and commercial

This work to adapt the wind turbines takes place 100 metres above the

activities in Europe (Spain, the UK, Portugal, France, Germany, Italy and

ground on fully assembled wind turbines and requires sanding, cleaning

Greece), the US, Brazil, Mexico and Australia, while counting markets

and painting the blades. The tasks are undertaken when there is little

including Japan, Ireland, Sweden and Poland as growth platforms. It

wind and no rain to ensure the safety of the specialised wind turbine

is continuing to roll out solutions to promote the coexistence of its

maintenance and operation workers. Each blade on the Cavar wind

renewable facilities, one of the foundations of the energy transition,

turbines is 65 metres long and up to 14 metres wide, so it can take a

and the ecosystems in which they are located. The company has

week to paint them.

launched two initiatives on several wind farms to improve the visibility of their wind turbines and to deter certain species of birds from the

Vinyl shapes to discourage birds of prey

areas of influence around the projects. The solutions are based on

The second of these initiatives consists of marking wind turbine towers

studies conducted by the Norwegian Institute for Nature Research and

with two vinyl transfers that look like staring eyes. These one-metre-

experiences at French airports.

diameter concentric circles are fixed at between 3.5 and four metres

Painting wind turbines black

from the base of the wind turbines. It has been shown that sticking these black shapes to the white base of the wind turbine tower is a

One such initiative involves painting one of the three blades black on

deterrent to birds of prey.

several wind turbines on wind farms in Cavar (111 MW) in Navarre; and

The solution has been implemented in seven wind farms in Burgos and

Zorreras (20 MW) in Zahara de los Atunes (Cádiz) in Andalusia.

has involved applying these vinyl shapes to more than 60 wind turbines

The project, which will be rolled out in some of the company’s other wind farms, is based on a study published by the Norwegian Institute

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made

on the Ballestas-Casetona, Cotera, Páramo Vega, Urbel del Castillo,

in Ita ly

FOR. . TEC SRL

Valdeporres, Viñas and Fuente Blanca wind farms. The project does not affect the structure of the wind turbine and has no impact on

Senza titolo-5 1

22/01/2014 12:08:51

the operational systems or electricity produced by these production plants. There are plans to install these vinyl shapes at another six wind farms in Burgos province, while the possibility of further extending the scheme is being analysed. This method has been tried and tested at Lourdes-Tarbes-Pyrénnés airport in south-eastern France and has proven efficient for keeping birds away. A 65% reduction in the number of birds of prey spotted in the airport area was observed when the vinyl shapes were used.

Competitive energy and environmental balance Iberdrola has fully integrated the conservation of the biological diversity of ecosystems into its strategy, demonstrating that competitive, clean and sustainable energy supply can effectively coexist in balance with the environment. The company plans to achieve “no net loss” of biodiversity by 2030, by committing to the net positive impact of new infrastructure developments. In this regard, it has carried out more than 1,450 measures to protect biodiversity in the last three years alone, combining renewable project development with the conservation of the biological diversity of ecosystems and caring for flora, fauna and natural heritage. Among other initiatives to achieve its sustainability goals is reforestation, with the launch of the Trees Programme, whereby Iberdrola will plant 20 million trees by the end of the decade, with which it will capture approximately six million tonnes of CO2.

PAINT STRIPPING OVENS Forni pirolitici per termosverniciatura e...

Sverniciatura bilancelle

Sverniciatura serbatoi gas

Rigenerazione motori elettrici

Pulizia estrusori

Restauro carrozzerie

Hooks paint stripping

Gas tanks paint stripping

Electric motors regeneration

Extruders cleaning

Body work restoration

For. Tec. Forniture Tecnologiche S.r.l. – Waste Incinerators Manufacturer Via Nazionale Appia Km. 186,900 - Francolise (CE ) – ITALY Tel. +39 0823/88.11.05 Fax. +39 0823/88.28.89 P.IVA. 02913520611 – REA 205421

mail: info@fortec-inceneritori.it web: www.fortec-inceneritori.it

BRAND-NEW

Graco Launches the New IniFlex Colour Change Platform Graco introduces IniFlex, a new colour change platform that offers infinite flexibility to industrial finishing automation.

raco has launched IniFlex, the new platform of colour change

IniFlex is suitable for almost any application requiring compact colour

components that gives manufacturers the flexibility they

change valves. The equipment is composed, for example, of:

need to reduce colour change times and flushing waste and

• painting robots with on-arm colour change capability;

to use less solvent.

• reciprocators with automatic paint spray guns;

The innovative design of the colour change valve assembly causes it

• single and plural component mixing systems.

to flush cleanly and avoids accumulation: fewer empty spaces require less solvent and allow customers to save money.

For further information: www.graco.com

The IniFlex new colour change platform by Graco.

The innovative design of the colour change valve assembly causes it to flush cleanly. The equipment is composed of painting robots with on-arm colour change capability.

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The new frontier for the mass painting

The perfect solution For painting and/or coating automatically and quickly small parts (metals and not) in batch, e.g. : buttons, bolts, screws, springs, O-rings and much more. The new process An automatic precise control of air and paint flow allows you to obtain a perfect wettability of the pieces in any cycle phase. New temperature control Reliable, accurate, economic. The Data Management The new control SW stores all process data, for a precise consumption and production costs control, and supports you proposing a plan of preventive maintenance operations.

4.0 Rotover MES Easy and interactive production planning system for one or more machines. A data-base of working cycles accessible from every machine and easy to be updated: 4.0 interconnection. Multifunctionality Interchangeable drums of various shapes, sizes and geometries, designed for different possible types of items and for different materials. Customer Service Send a test batch and Imel will prepare for you the optimized cycle for your production. All machines are connected to Imel Service Center for a real time support. On the side of the operator Easy and immediate control software. New design Ergonomic, user friendly with no exposed cables and pipes.

Find out more, Scan the QR code to add the contact of our product manager to your device.

IMEL SpA – Via Divisione Julia 10 – 33033 Codroipo, UD – Italy – T +39 0432 908578 – info@imelspa.com – www.imelspa.com

HIGHLIGHT OF THE MONTH

Alufinish Has Been Building on Trust for Fifty Years Thomas Sondermann Alufinish GmbH & Co. KG - Andernach, Germany

thomas.sondermann@alufinish.de

Trust is the foundation of a functioning economy. Well aware of this, Alufinish GmbH & Co.KG (Andernach, Germany) has been building its network on trust for fifty years now. On its fiftieth anniversary, the company is now looking back on a period marked by growth, international relations, and numerous technical evolutions.

ounded on 9 August 1972, Alufinish started out as a manufacturer

“We were able to deliver to our first customers even by bicycle,” Alufinish

and supplier of products for the chemical surface finishing of

co-founder Otmar Monreal remembers this time fondly.

metals in Mülheim-Kärlich, in Rhineland-Palatinate. In its first

Alufinish’s network quickly grew and soon independent deliveries were

building, there was just enough space for a warehouse and a few

no longer possible. While the first international partners expanded

offices. Here, six employees carried out all coordination, processing, and

the Alufinish network, the Mülheim-Kärlich plant had also become too

shipping activities.

small. The company thus moved to Andernach, into a larger building.

Several customers were quickly added and, at a time when there

Even today, it is known by its location, as “Alufinish Andernach”. As its

were far fewer logistics requirements, many orders were delivered

international network continued to grow, the rules and laws governing

independently with the company’s own trailer.

the supply of process chemicals also became more complex.

Alufinish was founded in a small building in Mülheim-Kärlich.

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In 2020, there was a change of management. Dr. Nils Monreal and Stephan Zegers are now leading Alufinish.

HIGHLIGHT OF THE MONTH

Technology also changed rapidly during that time.

Whereas orders were initially processed on a typewriter, the first computer was installed in 1985. At international meetings and events, Alufinish met many friends and partners that are still an important part of its international network today; however, navigation systems and mobile phones were still a rarity at that time, so people helped themselves with painstakingly drawn directions and a walk to the nearest phone box. “During our many journeys to international customers and partners, some vehicles also met the end of their life on the way!” says Otmar Monreal. As the growth of the Alufinish network continued, more technical innovations were implemented. And, in 1998, in addition to the delivery of the chemicals for the first chrome-free façade, Alufinish found its way onto the internet. The company’s first website presented the firm and its products, also including the directions to Alufinish Andernach to be printed out. From 2000 onwards, other numerous partners were added, from Ukraine to Spain and Mexico, and they brought Alufinish the strength that distinguishes it today. Even with the change of management in 2020, Dr. Nils Monreal and Stephan Zegers will continue this path in order to always keep working, as has now been the case for fifty years, on the company’s best patent: building on trust.

Well sorted, every nook and cranny of the old hall was used to maximise storage capacity. The first computer workstation at Alufinish in 1985.

Visit us: Hall 1, Booth 1210 Surface Treatment with Openair-Plasma® improves Color Fastness and Adhesion

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BRAND-NEW

Adapta Reduced CO2 Emissions by 6.2% In line with its firm commitment to achieve carbon neutrality by 2050, Adapta reduced its average emission intensity by 6.21% in the 2018-2020 period compared with 2017-2019, for classes 1, 2, and 3. This is why it has been included in the Spanish Ministry for the Ecological Transition and the Demographic Challenge’s Register of Carbon Footprint, Offsetting, and CO2 Absorption Projects under the label “Calculo y Reduzco” (Calculation and Reduction).

n 2018, 2019, and 2020, Spanish powder coating manufacturer

• replacement of office and laboratory air conditioners with more

Adapta Color S.L. carried out several actions to reduce its greenhouse

energy-efficient devices;

gas emissions. 2017 can be considered as this endeavour’s starting

• acquisition of new machinery with frequency converters and high-

point, since it was the year in which the company initiated its climate

performance motors;

change strategic plan and for which sufficient data was made available

• new refrigeration equipment with low global warming potential (GWP)

for the calculation of greenhouse gas emissions.

gases; • a new 38.7-kWp self-consumption photovoltaic system; with this new

The targeted actions developed by Adapta in the financial years 2018,

system, 1886 photovoltaic panels have already been installed on the

2019, and 2020 to reduce its greenhouse gas emissions included as

roofs of the Adapta plant, for a total power output of 338.7 kWp.

follows: • replacement of the diesel vehicles in its commercial fleet with hybrid

Adapta has decided to publish this statement in order to facilitate the

vehicles;

verification of its greenhouse gas (GHG) inventory and present its GHG

• replacement of the lighting systems in all offices, laboratories, and

emission values in a transparent manner to all stakeholders.

buildings (both indoor and outdoor) with LED tubes and screens;

The statement has been prepared in accordance with the requirements

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BRAND-NEW

of the standard ISO 14064-1:2012 “Greenhouse gases - Part 1: Specification with guidance at the organisation level for quantification and reporting of greenhouse gas emissions and removal”. The verification of the greenhouse gas (GHG) inventory is a part of the company’s integrated management system. Here are the main milestones in this regard: • 1998: certification of the Quality Management System in compliance with ISO 9001; • 2001: certification of the Environmental Management System in compliance with ISO 14001; • 2017: verification of the Environmental Product Declaration (AENOR’s GlobalEPD programme) for the products ADAPTA VIVENDI and ADAPTA VIVENDI SDS; • 2018: drafting of the Sustainability Report; • 2021: verification of the company’s GHG inventory in compliance with ISO 14064.1:2012 for the years 2017, 2018, 2019, and 2020. For further information: www.adaptacolor.com

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over 60 years of experience in surface finishing lines

www.trasmetal.net

BRAND-NEW

The industry’s response to the Russia-Ukraine war

Jotun Donates to Red Cross/Red Crescent to aid Ukraine’s Civilian Population To contribute to the urgent need for humanitarian support to the civilian population in Ukraine, Jotun donated NOK 1 000 000 to Red Cross/Red Crescent. The company also announced the suspension of its operations in Russia until further notice.

otun is supporting the Ukrainian civilian population through a donation

Following deep concern about the unfolding conflict in Ukraine, Jotun

of NOK 1 000 000 (about 100.000 EUR) to the Red Cross/Red Crescent,

also announced to have suspended operations in Russia until further

which has been present in the country for eight years, serving over 3

notice, where the company has been present since 1989 and has had

million people in need in the conflict areas.

its own local production since 2017. With more than 300 employees in

The support will be directed at maintaining critical societal functions

the country, Russia accounts for between 2 and 3 per cent of Jotun’s

such as basic infrastructure and health care supplies and equipment. In

operating revenues.

addition, there is an urgent need for water supply, food, warm clothes,

“We have been operating in Russia for a long time. We have a good

and basic sanitary standards.

team and a modern production site there. However, based on an overall

“A part of our Corporate Responsibility strategy is to take responsibility in

assessment, we now find it both right and necessary to shut down”,

the areas where we operate, and Jotun want to contribute economically

Jotun’s President and CEO Morten Fon commented. “Jotun is deeply

to aid the emergency situation in Ukraine. By choosing Red Cross/Red

concerned about the humanitarian consequences of the ongoing crisis”.

Crescent as our partner, we know that the money is spent according to

Jotun has no legal entity nor facilities in Ukraine. However, the company

our intention”, said Christian Espolin Johnson, Group Communications

has four employees in the country. The safety of the employees in Ukraine

Director.

and Russia is Jotun’s major concern.

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BRAND-NEW

The industry’s response to the Russia-Ukraine war

Hempel Announces Several Actions to Help Ukraine

Your Leaders in Zero Liquid Discharge

Hempel will support the Ukrainian population, the Red Cross and other NGOs.

he coating manufacturer Hempel has

population and those who have already fled the

announced that it is taking several actions

country. The fund will be equally disbursed between

to support Ukraine during the crisis that has

seven NGOs (UNICEF, Save the Children, Red Cross,

recently involved the country.

Médecins Sans Frontières, SOS Børnebyerne, Human

The company is focusing its efforts on supporting

Rights Watch and UNHCR) to immediately deliver

the employees with Ukrainian relatives by offering

essential humanitarian aid.

financial support to cover the costs of evacuation

From a business perspective, Hempel has already

and temporary housing, as well as assistance

suspended all deliveries in and out of Russia until

in finding appropriate accommodation and

further notice. The company is evaluating current

psychological support through a network of crisis

orders on a case-by-case basis whether it is obliged

psychologists.

to deliver the order and whether regulators permit

Hempel is also encouraging its Danish colleagues

to do so.

to support the Red Cross with donations and has

“We are keeping a watchful eye on the situation as

announced that it will double the donated amount.

things develop. We always adhere to international

In addition, through the Hempel Foundation,

rules and sanctions and we expect additional

the business has granted a €1 million fund for

sanctions to be implemented shortly, with which we

emergency relief to help and support the Ukrainian

will act in accordance”, commented Hempel.

Industrial Wastewater Treatment

Simple Principle

Covestro Supports Ukraine with Targeted Donations Covestro provides Ukrainian refugees with targeted donations and support.

ollowing the humanitarian emergency in

humanitarian organizations in order to be able to

Ukraine and neighbouring countries, Covestro

provide rapid assistance to refugees.

has decided to help Ukrainian refugees with a

In addition, the Covestro’s facilities based in Slovakia

targeted aid package.

and Poland, countries where many Ukrainian refugees

The chemical manufacturer has donated € 250,000

are arriving, have been provided 40,000 euros, which

to United Nations Refugee Aid (UNO Flüchtlingshilfe),

will be donated to local humanitarian organizations.

the German partner organization of the UN Refugee

Covestro CEO Dr. Markus Steilemann stated: “Violence

Agency (UNHCR). UNHCR has been active in

must never be the answer to any conflict. I am

Ukraine since 1994 and has offices and warehouses

shocked and saddened by the terrible events! The

throughout the country for the distribution of

violence must stop before more people lose their

humanitarian aid; while in neighbouring countries, the

livelihood, are injured or killed. Supporting people in

organization supports the preparations and ongoing

need is a matter close to our hearts.”

operations of the respective local authorities and

Effective Result

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BRAND-NEW

The industry’s response to the Russia-Ukraine war

Teknos Suspends All Its Operations in Russia and Supports Ukraine with Donations The Finnish family-owned company Teknos has suspended its activities in Russia and will focus on helping its Ukrainian employees.

eknos has recently announced that it will suspend deliveries and

ready to react and act in any ways possible to keep our people safe and

all operations in Russia and Belarus until further notice.

to support actions for peace and help for those in need”, stated Paula

In addition, the company has expressed its concern for the

Salastie, the CEO & owner of Teknos Group Oy.

Ukrainian employees and all the population and is working to support

“This war will for sure have some impact on global supply chain. These

and help them.

crisis and uncertain situations have a tendency for further global spikes

“At Teknos, we are shocked and heartbroken about the war in Ukraine.

on at least oil, gas and other energy prices that will for sure at some

Our minds and hearts are with all the people affected by the war, either

point have some impact on our raw materials. Currently we do not see

directly or indirectly. Teknos is a Finnish family-owned company, but

any immediate shortages and delivery issues as a result of the escalated

we operate globally, also in Ukraine and Russia. Our top priority is the

situation. This situation is of course subject for change if the crisis will be

safety and wellbeing of all our employees and their families in Ukraine

prolonged”, also added Fredrik Calenius, the Chief Procurement Officer

and do our outmost to help them. As a company, we condemn the

of Teknos Group Oy. Furthermore, there is currently a huge need for

Russian war and stand fully behind all the sanctions imposed. As part

medicine, food and other necessities in Ukraine as supply chains have

of our actions of solidarity with Ukraine, we suspend our operations in

been disrupted and many shops and pharmacies are closed. Teknos

Russia. Due to the hostilities, we were forced also to suspended all our

also donated € 50,000 to provide medicine and other humanitarian

activities in Ukraine. We continue to follow the situation carefully and are

needs to the Ukrainian people.

Tikkurila and PPG Support Ukraine Tikkurila and PPG send humanitarian aid to help Ukrainian refugees.

o help and support the hundreds of thousands of Ukrainian citizens

such as food and hygiene items and supports countries experiencing an

forced to flee their homes over the past week, Tikkurilla, together

influx of Ukrainian refugees.

with its owner PPG, have sent humanitarian relief and longer-

Employees also collaborated through donations to charities dedicated to

term recovery support. In particular, to respond to the immediate and

providing humanitarian support to Ukrainian refugees.

essential needs of refugees arriving in the countries where the companies

Finally, the companies are committed to responding to the needs that

are present, both have donated funds to some relief organizations that

will emerge in the coming weeks and months to continue supporting the

address immediate and essential needs. They collaborate with Polska Akcja

Ukrainian population.

Humanitarna, a relief organization in Poland that offers food and other

“In times of crisis, we fulfill our company’s purpose to protect and

forms of support to those arriving from Ukraine; International Committee

beautify the world by helping our non-profit partners adapt to emerging

of the Red Cross, an organization that provides emergency supplies; and

challenges and provide immediate responses. We are committed to

People in Need, an organization based in the Czech Republic and present

supporting these organizations who are providing direct emergency aid”,

in Ukraine since 2003, which provides humanitarian aid for basic needs

the companies stated.

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www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

BRAND-NEW

The industry’s response to the Russia-Ukraine war

BASF Donates €1 Million in Emergency Aid to Help Ukraine BASF is providing the German Red Cross with €1 million in emergency humanitarian aid for Ukraine.

ASF donated € 1 million to the German Red Cross (GRC) to provide

German Red Cross will also provide psychosocial support.

humanitarian aid to Ukraine. After the attack on Ukraine ordered

“There is a war going on in Ukraine. The suffering for the civilian

by the Russian government, the population is experiencing an

population in the country is immense,” said Martin Brudermüller,

escalation of violence and hundreds of thousands of civilians are trying to

Chairman of the Board of Executive Directors of BASF. “We want to help

leave their homeland.

these people and therefore quickly decided to provide this emergency

GRC is supporting its sister organization, the Ukrainian Red Cross

aid.”

(URC), to help and provide relief to the population. Specifically, GRC

In addition, many employees of the company around the world have

plans to provide basic necessities to people in Ukraine and people

expressed their willingness to donate. BASF will offer the opportunity to

arriving in neighbouring countries: food, clothes, hygiene kits, but also

donate in the coming days. In addition to emergency humanitarian aid,

communication devices such as charging devices for mobile phones. The

BASF will double the amount raised through employee donations.

Clariant Suspends All Its Businesses with Russia Clariant is supporting its almost 150 Ukrainian employees and their families and has suspended the activities in Russia.

he specialty chemicals company Clariant has recently announced

to support them. We join them in hoping that this brutal violence will

that it has suspended all its businesses with Russia and will help

end soon. Continuing to do business under these circumstances is

its 146 employees and their families in Ukraine. The company had

incompatible with our purpose and values. Therefore, we have decided

a sales office and a laboratory in Moscow and its Russian operations

to suspend all business with Russia with immediate effect,” stated Conrad

contributed to approximately 2% of the annual sales.

Keijzer, the CEO of Clariant.

“We strongly oppose Russia’s war against the Ukraine and support the

In addition, many employees have taken personal initiatives to support

vote of the UN General Assembly that the Russian government must

their Ukrainian colleagues and charities. Clariant encourages these

immediately stop the aggression, withdraw its troops, and abide by the

activities and, through the Clariant Foundation, has also made a donation

rules of the UN Charter. Our thoughts are with our 146 employees and

to UNICEF to ensure that children and families in need can be helped

their families in the Ukraine and we are doing everything in our power

right away.

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BRAND-NEW

The industry’s response to the Russia-Ukraine war

Solvay Suspends Operations in Russia and Provides Aid to Ukraine Solvay has donated €1 million to support Ukraine and has decided to suspend its activities and new investments in Russia.

xtremely concerned about the humanitarian crisis that is unfolding

Additionally, private employee donations will also help address growing

following the hostilities in Ukraine, Solvay has decided to suspend

humanitarian needs.

its operations and new investments in Russia. Additionally, Solvay

“Solvay is deeply saddened by the loss of life and suffering in Ukraine”,

will suspend dividend payments from Rusvinyl, an independent 50:50 joint

said Ilham Kadri, CEO of Solvay. “Our top priority has been the safety of

venture in Russia.

our colleagues in Ukraine. We are taking action to support the ongoing

Through the Solvay Solidarity Fund, the Belgian chemical company

humanitarian efforts to ease the suffering of those impacted by this crisis.”

donated 1 million euros to the Belgian and International Red Cross in

“We stand behind all our employees, including our Ukrainian and Russian

support of relief efforts for affected civilians in Ukraine. The funds will

colleagues in such an unprecedented crisis, and will provide all the

help provide access to clean water, medicine and medical equipment,

necessary support, including salaries and benefits. We thank them all for

repair vital infrastructure and improve the living conditions of families.

their continued dedication and resilience”, continued Dr. Ilham Kadri.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

161

BRAND-NEW

PPH707 EXTi Electrostatic Sprayer: Premium Finish at Optimised Costs The SAMES KREMLIN PPH 707 EXTi optimises installation costs, generates high productivity, and delivers a premium finish. It features fingerless external charging while reaching the most difficult parts in car finishing.

AMES KREMLIN has waited until 2022 to enrich its 7 range with

combined with an exclusive air flow device around the electrodes

an electrostatic sprayer with external charge without fingers.

protecting them from the return of paint droplets.

However, the wait and results were well worth it. The PPH 707

Tests in the laboratory and on industrial sites have been performed.

EXTi, intended for waterborne paints, does not only claim the low

It is possible to work up to 8 hours without stopping to clean the

investment costs specific to this technology, it is a qualitative piece of

applicator.

equipment designed to work for hours without stopping to clean it,

The PPH 707 EXTi saves paint: its transfer rate is 8 to 12 points higher

and it contributes also to achieving premium finishes.

than that of non-electrostatic sprayers.

Finishes: SAMES KREMLIN Automotive quality SAMES KREMLIN uses patented devices which have made its reputation in the automobile industry: high-speed magnetic bell cup

It is compatible with SAMES KREMLIN’s patented PaintSave system. The result is paint losses are reduced by 50% during colour changes and hundreds of litres of material are saved each year.

(up to 70,000 rpm), dual-flow air shrouds to control and direct the

For vehicle interiors cut-ins and bumpers

micro-droplets of the paint jet. The PPH 707 EXTi offers a complete

The quality of finish and the compact feature of the new sprayer makes

range of rotating bell cup to adapt perfectly to vehicle interiors cut-ins

it suitable for vehicle interiors cut-ins where it will easily reach hard-to-

and exteriors as well as, bumpers.

reach parts like windshield aprons, hinges, etc. It is also of interest to

Up to 8 hours of non-stop operation without stopping for cleaning

plastics manufacturers for the continuous application of waterborne paints on bumpers with the most complex shapes.

Contamination is significantly reduced thanks to the judicious choice of non-conductive materials, particularly for the crown of electrodes,

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For further information: www.sames-kremlin.com

EVOLUTION TO E-MOBILITY C O AT I N G

I M P R E G N AT I O N

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INNOVATIONS: PRESENT&FUTURE

Energy Consumption of a Paint Shop Reduced by 30% Gabriele Lazzari, ipcm®

Energy efficiency is a key aspect of being competitive in today’s marketplace. RA Energy works with small and large companies to carry out energy audits and find the right solutions for every need. From energy optimisers to photovoltaic systems, a factory can thus reduce its consumption by 30%.

he industrial coating sector’s focus on its own environmental

Always attentive to new developments, ipcm® has identified a new

impact is growing, leading companies to prefer low-emission

potential partner to successfully overcome this challenge: RA Energy.

energy solutions.

An innovative partner

associated costs, which is also becoming increasingly important due to

RA Energy was established in Concesio (Brescia, Italy) in 2010 based

the rising prices of energy and raw materials.

on an initiative of the industrial group Metal Work S.p.A., aimed at

This has the secondary effect of reducing energy consumption and its

The Enersolve energy optimisers provided by RA Energy.

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INNOVATIONS: PRESENT&FUTURE

The energy optimiser in a production site.

laying the foundations for a strategic approach to energy efficiency

Not only equipment, but also targeted technical advice

and for the research and development of sustainable technologies.

RA Energy helps businesses reduce energy consumption, e.g. by

With an ESCo certification for the management of white certificates

installing energy optimisers, or self-produce energy with photovoltaic

(negotiable certificates recognised against a reduction in energy

systems. “Energy optimisation is a technology that is not widespread

consumption obtained through efficiency improvement interventions),

yet, unlike energy production from biomass or gas plants, but in

this company deals with the design and implementation of primary

which we are investing a lot. Depending on customer needs, auto-

energy consumption optimisation and saving projects, offering flexible,

transformers are installed downstream of the general transformer or

turnkey solutions also through the Energy Performance Contract (EPC)

in an individual department, in order to lower input voltages and thus

approach.

reduce the energy consumption of all downstream devices,” explains

All the technologies supplied by RA Energy are developed and tested at

Luigi Duina, the CEO of RA Energy.

the group’s industrial site and they must pass all the required standards

However, what characterises this company are not just the solutions

in terms of efficacy, cost-effectiveness, and environmental impact. The

it sells, but also the whole process of analysis and consultation

firm’s target customers are all kinds of energy users, whether in the

performed with a view to reducing consumption and actively producing

public or private sector. Current customers include farms, foundries,

energy. In fact, RA Energy supports every customer through a path

metalworking plants, hospitals, office and retail centres, restaurants,

approaching energy efficiency progressively and gradually, which

and hotels, with the latter having to meet particularly stringent

begins with an energy audit at the factory in order to understand what

architectural and environmental requirements.

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74

165

The energy optimisers in the headquarters of RA Energy in Concesio, before being transferred to the clients’ plants.

energy consumption depends on, what kind of electronic equipment is

Savings of up to 30%

present, and how it is composed.

“An energy optimiser placed downstream of the general transformer,

Network analysers are therefore positioned in the main utility

for example, allows reducing consumption by 5%. A company that

switchboards and by inductive and inverter loads, normally divided

consumes 3 million kilowatt-hours per year can pay back its investment

into categories such as driving force, compressors, work centres, and

in less than a year. Obviously, the higher the company’s consumption,

offices with all their connected utilities.

the greater the efficiency: three-shift operations can become three

This allows breaking down the distribution of energy consumption

times as efficient as one eight-hour shift. With all our solutions, for

as a percentage of the annual consumption. Then, it is possible to

example, a paint shop can reduce its energy consumption by around

take targeted action and install one or more machines and systems

30%,” states Duina.

appropriate to the size of the company and its working hours. “We

Environmental and economic benefits of adopting RA Energy’s energy

offer various customer-specific solutions, from replacing compressors

saving technologies:

with inverter compressors or installing LED lighting systems to

• Tonnes of CO2 released into the atmosphere: -6,800

adopting energy optimisers, heat pumps with an electric driver, or

• Tonnes of oil consumed: -2,900

photovoltaic systems. In addition, we use datalogs to store and analyse

• Dispersed compressed air: -25%

consumption data, in order to further optimise the energy efficiency

• Energy costs with LED lighting: -50%

measures,” indicates Duina.

• Photovoltaic self-consumption: +80%

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WHERE VISION BECOMES INNOVATION. ALUMINIUM 2022.

27 – 29 September 2022 Exhibition Center Düsseldorf, Germany

Use ALU2022_ipcm and get a free ticket!* *Tickets available from April 2022

ART WITHIN SURFACES

Artifacts Never Displayed Before and a New Addition to the Historic Westminster Abbey: AkzoNobel Coated 500 Window Frames for the Project Through Weston Tower, the first tower in 300 years to be built in Westminster Abbey, the public can access Queen Elizabeth II’s Diamond Jubilee Galleries, an exhibition area that houses priceless historical treasures. The 500 window frames of the new tower were coated with super-durable powder coatings provided by AkzoNobel.

estminster Abbey is one of the world’s most famous churches,

history of the UK,” stated Tomasz Kluczewski, the Regional Director

welcoming over two million worshippers and visitors every

North Europe for AkzoNobel Powder Coatings.

year. To celebrate Queen Elizabeth II’s jubilee, it has been

The £23 million Weston Tower is the most significant addition to

at the centre of an ambitious project: the construction of a tower to

Westminster Abbey since 1745. It is a 30 metres tall and 6 metres wide

grant access to a new area of the abbey that features an art gallery full

8-point star-shaped structure inspired by the 13th century Westminster

of magnificent artifacts. AkzoNobel collaborated with the project by

retable, England’s oldest altarpiece. The Weston Tower, designed by

providing its Interpon products, in order to coat the over 500 window

Ptolemy Dean Architects, provides staircase and lift access to the new

frames of the tower.

Queen’s Diamond Jubilee Galleries, an area that has never been open to

“As the undisputed leader in powder coatings, we are very proud to

the public before.

have contributed to such a significant project, which is integral to the

The Weston Tower.

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The windows of the Tower, their frames were coated with Interpon products.

ART WITHIN SURFACES

The galleries are located in the medieval Triforium: an area of almost 16 metres above the floor of the abbey itself, that has lain unused for several centuries. The Queen’s Diamond Jubilee Galleries were officially opened by Her Majesty the Queen herself during the summer of 2018. The exhibition space displays over 300 precious regal and religious artifacts, many of which have been on display for the first time. “The views are breath-taking; the space astonishing; the displays fascinating. Visitors can now gain far greater insight into the life and history of the abbey than ever before,” commented the Very Reverend Dr. John Hall, the Dean of Westminster. The new Weston Tower features 500 leaded windows and each window frame has been coated with the superdurable powder coating Interpon D2525 Anodic Bronze provided by AkzoNobel, an attractive matt and metallic effect finish used as an alternative to anodised aluminium with minimal environmental impact. Additionally, the BPP600 barrier prime had been applied prior to finishing, providing a perfect colour match and long-lasting protection. “The powder coating was very easy to apply and the efficiency was superb,” explained Andris Valters, the owner of Hereford Coatings, the company in charge of applying the coatings on the window frames. © AkzoNobel

For further information: www.akzonobel.com

Westminster Abbey and the Weston Tower.

24–26 MAY 2022

SOURCE, NETWORK AND COLLABORATE

11:00 AM TO 7:00 PM

DUBAI WORLD TRADE CENTRE

AT THE LARGEST AND MOST SIGNIFICANT INTERIORS EVENT IN MENA REGION

INDEX is the largest international interior and fit-out trade show in the Middle East, connecting the world’s leading brands and manufacturers with regional hospitality, residential, commercial, and retail buyers.

Co-located with

Organised by

To get in touch +971 4 438 0355

D U B A I

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www.indexexhibition.com

info@indexexhibition.com

ART WITHIN SURFACES

Momentum (2008), Gerstein’s largest outdoor sculpture in Singapore.

Nature Lover (2020).

Laser Technology and Powder Coatings for Outdoor Colourful Sculptures that Resist all Kinds of Weather Conditions Large-scale outdoor sculptures coated with bright colours are always eye-catching. To keep attract visitors, however, they need to maintain their properties over time despite being exposed to all kinds of weather conditions. To ensure this, the sculptor David Gerstein has even added a spray booth in his workshop in order to finely paint and protect all the artworks.

sing primary colours and subjects from day-to-day life, David

David (Dudu) Gerstein is an Israeli painter, sculptor, draftsman and

Gerstein has become a second-generation pop-artist renowned

printmaker who began his career as a figurative painter depicting scenes

for his colourful metal sculptures than can be found in public

from his childhood. At the end of the ‘70s the artist decided to expand

spaces at every corner of the Earth.

the limits of two-dimensional painting, so he started to cut out the

The sculptures are designed to maintain an excellent aesthetic

main subjects of each painting and to cancel the background creating

appearance despite being exposed to several climatic and weather

a unique and iconic cut-out image, free standing in space, without the

conditions. In order to transform metal into art, the sculptor employs

standard and traditional square frame.

laser technology and a combination of powder basecoats and clearcoats

That led him to focus on sculptures mostly made by wood and use

that are applied in a painting booth inside the artist’s workshop.

industrial paints as coating. Through the use of primary colours and

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ART WITHIN SURFACES

subject matters from day-to-day life, Gerstein

the artworks was even bought by professional

created a personal variation of pop-art

cyclist Lance Armstrong and referred to in one

style which he himself defined as “second-

of Stephen King’s novels.

generation pop-art”, leaving behind the

At the same time however, Gerstein developed

monochromatic pallet of oil and watercolours

a great interest in public spaces, creating

and using instead vibrant, design-oriented

more than 40 sculptures in public squares

colours.

and plazas in Israel alone. Later, he created

From the mid ‘90s the sculptor and painter

many more large-scale outdoor sculptures

began to experiment with laser-cutting

in England, France, Sweden, Italy, China and

technology, soon becoming the first artist

South Korea. In his own paint-shop, Gerstein

to create multi-layered cut-out steel wall-

usually applies first a matte basecoat on a

sculptures. Most of the new vibrant three-

previously powder coated surface and then a

dimensional sculptures combines his first

clearcoat, allowing the artworks to maintain

subject, nature from everyday life, with cyclists.

their brilliance while conveying also protection

These themes can be seen in Nature Lover

against atmospheric agents and mechanical

(2020), with a bicycle in silhouette combined

damage.

David Gerstein.

with a burst of brightly coloured butterflies that surround and follow the rider. The style

For further information:

made him renowned worldwide, and one of

www.davidgerstein.com

international PAINT&COATING magazine - MARCH/APRIL 2022 - N. 74 UCIMU-SISTEMI PER PRODURRE

075/2018 BMXX18R

171

SPECIALIZED TRAINING

How Much Does New Tertiary Technical Education Affect Success in Finding a Job? Monica Fumagalli, ipcm®

It is called tertiary education and it consists of a new post-diploma study pathway, which is attracting a lot of interest within the Italian education system.

fter high school, most students are faced with a choice:

selection. Training courses can last two or three years, or 1800/2000

trying to enter the world of work immediately or choosing a

hours in total. Internships must account for at least 30% of the total

university pathway. However, a few years ago, a third option was

hours and at least 50% of the teachers must work in the industry. At

introduced into the Italian education system, namely tertiary technical

the end of this educational pathway, students are awarded a Higher

specialisation. This can act as a bridge between the school and industrial

Technical Diploma with the certification of skills corresponding to level 5

worlds, the lack of which has always been emphasised not only by

of the European Qualification Framework. In addition, Higher Technical

recent graduates searching for a job in line with their needs, but also,

Institutes offer the possibility of doing internships abroad, thus enabling

and perhaps above all, by representatives of the manufacturing industry,

students to acquire technical skills that are among the most sought-after

who are confronted on a daily basis with the selection of employees who

by international companies.

often do not match requirements due to a lack of practical skills. This need is currently being met by Higher Technical Institutes, which are already widespread in other European countries and which entered the Italian education system about ten years ago, offering all-round training in various production sectors, and by technical courses such as those organised by ipcm® Academy, with a high degree of specialisation aimed at meeting the demand for personnel in even more specific industrial sectors, such as surface treatments, for example.

What are Higher Technical Institutes? According to the definition of Indire, the Italian National Observatory of phenomena linked to the development of tertiary education, “Istituti Tecnici Superiori (ITS) are the first tertiary vocational training option offered in Italy in line with what has been done in other European countries for some years now. Created in 2010 to train higher technical experts in strategic areas for economic development and competitiveness in Italy, these institutions are closely linked to the manufacturing industry and they train specialised middle managers who can help companies exploit the potential of Industry 4.0 solutions.”1 Higher Technical Institutes take the legal form of foundations, i.e. that particular form of private institution used by public bodies to carry out public benefit activities with the cooperation of private companies. They are open to all those who have obtained an upper secondary education diploma or a four-year diploma + one-year supplementary training, after 1

https://www.indire.it/progetto/its-istituti-tecnici-superiori/

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SPECIALIZED TRAINING

Employment data

to studying by selecting this third option3. Through a journey lasting

According to the latest Indire monitoring data, more than 80% of those

several months among some of the 117 ITS set up in Italy, the article

who attend a Higher Technical Institute find a job within a year of the

emphasises the importance of these structures as a “strategic asset

end of the course and, out of these, 92% find it in a sector consistent

for the Italian manufacturing industry and a new way of offering post-

with their specialisation. The success of this new training pathway

diploma training since their creation over ten years ago”.

lies precisely in covering different thematic areas, from mechatronics to sustainable mobility and from digital processes to fashion, thus

Tertiary technical training offered by ipcm® Academy

directing students towards specific, well-defined industrial fields while

ipcm® Academy, the training division of eos Mktg&Communication,

increasing motivation. Indeed, Indire’s 2021 monitoring data reveal

the publisher of the ipcm® magazines, has also been active in the field

that “graduates from the courses completed in 2019 were 3,761,

of tertiary technical education for over ten years. Specialised in the

73.7% of enrolled students. A technological area-based analysis shows

training of technicians for the surface treatment of metals and plastics,

that the best results in terms of training success were achieved in the

its courses are aimed both at young people who are looking for job

New technologies for Italian-made productions area (79.1%) and, in

opportunities in the industrial coating sector and at professionals who

particular, in the Mechanical systems area (85.5%).”2

already work in this industry, but would like to deepen their knowledge

The fact that these tertiary education institutes act as a bridge with the

of certain processes in order to improve their know-how and become

world of work has prompted even university students and graduates to

key resources in their departments.

apply for admission. An article published last November in “Il Sole 24

One of the Academy’s next goals is to create a full training course within

Ore” highlighted the fact that some of these people choose to go back

a new vocational school, open to young people finishing secondary school – an objective shared with Higher Technical Institutes. “We will

Zuccaro, A. (ed.), “Istituti Tecnici Superiori - Monitoraggio nazionale 2021 – Sintesi”, INDIRE, Firenze, 2021.

create synergies with companies from our industry in order to get these boys and girls into the world of work,” stated Paola Giraldo, the co-founder and soul of the ipcm® Academy, in an interview last year,

underlining that the lack of technical training and industrial culture represents a gap that needed to be filled. “There is a lack of technical graduates in all sectors: it is important to focus on the revival of technical education, which serves the whole productive system. The difficulties that companies find when selecting new candidates are precisely related to skills shortages and this is very damaging to our country, which is losing productivity, competitiveness, and innovation. The task of ipcm® Academy is to continue on the path of training coating technicians in order to fill this worrying cultural gap and to contribute to the relaunch of production activities, while still meeting the needs of those who already work in the sector for in-depth study and refresher courses.” This is why the specific training pathway offered by ipcm® Academy, with teachers boasting more than thirty years’ experience in the coating sector, helps new professionals enter this industry, offering so many job opportunities.

A new professional role: the Industrial Surface Finishing Process Technologist Thanks to ipcm® Academy’s collaboration with ASP Mazzini, in 2020 the Lombardy Region officially included the professional role of Industrial Surface Finishing Process Technologist in its Regional Framework of Professional Standards (QRSP). “The project,” said Paolo Rami, the director of ipcm® Academy, shortly after such recognition by the 3 https://www.ilsole24ore.com/art/its-asset-strategici-la-manifattura-bianchi-ora-15-miliardi-pnrr-AE7UIxt

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173

Lombardy Region, “stemmed from the need to train new professionals

and specific training requires high efforts both in terms of involvement

recognised at the national and European levels and able to organise

of the teaching staff, which, in the case of the Academy, is mostly made

and manage an entire coating process to guarantee proper corrosion

up of people still active in the world of work, and in terms of promotion,

protection. These technicians should not only be capable of performing

an aspect that proves to be critical also for Higher Technical Institutes,

destructive and non-destructive tests, but also of collaborating both with

“still little known by many families, students, and very often even by

an R&D office to design coating-ready products and with a production

secondary school teachers”, as the “Il Sole 24 Ore” article explains.

engineering department to find the most suitable protection system to

ipcm® Academy will continue its tertiary and vocational training activities

guarantee the durability of components in their intended environment.

because it believes that school and the industry can only be brought

Finally, they should be able to assess the adequacy of a company’s

together through specific and targeted educational pathways. As the

production processes, understand a customer’s technical documents,

epigraph of the latest Indire report reads, “The contemporary world of

prepare process management and control documentation from work

work is too mobile for the desire to do well in itself to be fully recognised

cycles to manufacturing and control plans, and coordinate production

and rewarded. Artisanship has a distinctive cultural trait, namely the

activities based on the technical and human resources available.”

objective value attributed to inner commitment and to one’s own work,

Conclusions

which is not recognised by contemporary society, more attentive to exchange relationships than to the beauty of doing something well

It is not easy for an educational institution to act as an effective bridge

without the need to receive anything in return (Giuseppe Varchetta,

between school and the industry. It is complex, first of all, because it

2020).”

requires balancing two elements: schooling, with the aim of providing an effective employment outlet, and the industry’s demands, which must be met. Secondly, because guaranteeing such excellent-quality

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For further information: www.ipcmacademy.com

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Surfex brings an essential focus to science and technologies, as well as the business and regulations issues that influence innovation, design, development, manufacture and supply of coatings, inks, adhesives and an array of allied and associated industries.

There is also the Cutting Edge programme – two days of R&D achievement presented by the universities of Birmingham, Cranfield, Durham, Nottingham, Salford, Sheffield & UCL. If you want to hear about what’s coming next, this is the programme for you.

Surfex is organised by OCCA – the Oil & Colour Chemists Association and is free to attend.

The Surfex exhibition features over 100 exhibitors and also its accompanying TechFocus programme. If you want to know what’s new on the market, find answers to technical challenges and source information for immediate use – this is where you will find it.

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THE MARKETING CORNER

Digital Marketing Trends 2022: Everything There is to Know Barbara Pennati eos Mktg&Communication Srl

info@eosmarketing.it

The latest reports speak of an increasingly digitalized world, which is moving at great speed towards more immersive experiences, new formats and new technologies. From recommerce and NFTs to cryptocurrencies, here are 7 digital marketing trends to keep an eye on in 2022.

the first thing to do is to know your audience. In fact, there is no

More and more people are using the Internet, translation tools and voice assistants

marketing strategy that can be defined as such that does not

The latest figures tell us that 62.5% of the world population uses the

nyone who approaches marketing for the first time is told that

take into consideration the needs, expectations and behaviours of its

Internet. This means that the gap between those who have access to the

audience. Therefore, it goes without saying that knowing how people use

internet and those who do not have it is getting smaller and smaller.

the internet and social media, what content they enjoy, what they prefer

The user base is therefore expanding and is destined to increase to

when it comes to the digital world and what are the latest trends in the

include a large part of the world population: to date, only about 3

sector is essential for planning a truly effective communication strategy.

billion people remain without internet, a sign that digitization is almost

Just a few days ago, We Are Social and Hootsuite published the Digital

everywhere.

2022 Global Overview Report, which every year brings us over 200 pages

But how do people use the Internet? 61% of users use the internet to find

of data and statistics on the digital world and which is invaluable for us to

information; 55.3% to stay in touch with friends and family and 53.1% to

understand in which direction the digital is heading.

stay updated on news and events.

In this article we will summarize the main digital marketing trends and

Therefore, intercepting our target’s queries and providing an answer

how brands can exploit them in their 2022 marketing strategy.

through interesting content and insights must remain our priority.

THE MARKETING CORNER

Other data that is worth dwelling on concern the use of automatic translation tools and voice assistants. Every week, 31.9% of users worldwide use tools to automatically translate online content into other languages. A percentage that is destined to rise when we look at the data country by country, i.e., Colombia (57%), Brazil (53.7%) or Poland (46.5%), to name a European country. This is linked to topic very important for SEO and often underestimated by marketers: not all users are looking for content in English, quite the contrary. Many people not only look for content in their own language but they also translate it with special tools when they land on pages in other languages. This means that, if our target is international, we must consider translating our content into multiple languages. Another interesting fact, which we find again this year, concerns the use of voice assistants. Every week, 24.1% of users worldwide use voice assistants like Alexa or Siri to search for information online. Therefore, our content must also be optimized for voice search, through the use of conversational and proximity keywords.

Social networks are a strategic touchpoint but organic engagement is decreasing Compared to 2021, the social media user base registered a +10.1%, reaching 4.62 billion users, a truly surprising figure. The average time spent on social media is 2 hours and 27 minutes, with YouTube leading

and for more and more time.

media are also important to follow brands

the ranking of the platforms on which people

Having said that, there’s a trend which we

from which we have already bought something,

spend the highest number of hours each

found last year and that is still valid: the overlap

brands from which we are considering buying

month on average: 23.7. However, if the

of social accounts. On average, a user uses 7.5

something and companies that are relevant to

YouTube figure is stable compared to that of

social platforms every month. Certainly not at

our work.

2021, TikTok, which has an average of 19.6

the same time nor with the same frequency;

In terms of advertising, global social media

hours per month, recorded a +48% compared

however, the fact remains that an overlap of

advertising spend exceeded $ 150 billion in

to last year.

audience from one platform to another is highly

2021, with social media ads accounting for

So, although the Meta apps continue to hold

probable.

around a third (33.1%) of the total digital spend.

the podium of the most used platforms in the

It is also interesting to note that 43.5% of users

This triggered a number of consequences.

world in terms of active global users, TikTok is

use social networks to search for information

First, while advertisers spent 14% more on

rapidly advancing in the ranking, attracting the

on brands, meaning that they remain an

social media ads in Q4 2021 compared to Q4

attention of an ever-increasing number of users

important touchpoint for every business. Social

2020, it also caused a 21.7% increase in CPM

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177

(an average of $ 9.13 per 1,000 impressions).

services through social media ads, a figure only

Paradoxically, this percentage is destined to

As a result, due to the higher average cost

slightly lower than that of TV ads (31,1%).

drop further, the greater the number of fans:

per impression, advertisers generated fewer

In terms of organic engagement, just under

for 100,000 fans, the average engagement rate

total impressions in the fourth quarter of 2021

1 in 4 users (23.2%) likes or actively follows

is 0.05%.

compared to the same period in 2020, despite

a brand on social media every month, while

These data confirm what we probably already

the higher ad spend.

almost 1 in 8 (12.2%) says they share the social

knew: engagement rates on social networks

But this has not led to a decline in the

media posts of brands at least once a month.

(some more than others) are decreasing

effectiveness of social media advertising.

Locowise data also indicates that Facebook

and vanity metrics are no longer sufficient or

Indeed, the latest GWI data tells us that more

pages can expect an average engagement

absolute proof of success.

than 1 in 4 Internet users (corresponding to

rate of 0.07%, a very low figure: only 7 fans out

Having said that, as the data cited at the

27.6%) discovers new brands, products and

of 10,000 react, comment or share any post.

beginning show, social networks remain an important touchpoint, so it is good to supervise them, especially if we have already created brand pages in the past. At the same time, in light of these data and taking into account the target overlaps between the various platforms, it is good to observe which social networks (or formats) give us the best results in terms of engagement and focus our marketing efforts on these. When it comes to advertising, given the higher spend in the face of a lower number of impressions, the advice remains to focus our budget on those campaigns that we believe are more valuable for our brand.

The future of e-commerce is recommerce and live commerce When it comes to e-commerce, it should come as no surprise that the growth that began during the Covid-19 pandemic shows no signs of slowing down and that even tourism-related e-commerce is recovering. Data from GWI shows that nearly 6 in 10 internet users (58.4%) buy something online every week, a figure that experts say is set to rise. On the other hand, a trend that is gaining momentum is that of “recommerce”, a popular choice for 1 in 7 users (14.4%) who buys a second-hand item every week. Even Facebook Marketplace and Instagram Shop report growing data, a sign perhaps that the barrier between the physical experience and virtual shopping is breaking down, convincing even the most cautious and doubtful buyers to make online purchases.

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THE MARKETING CORNER

A trend that will further help to narrow the differences between the

an animation, graphic design, GIF, audio/video file, or meme, that exist

in-store experience and online shopping is live commerce, which allows

on a blockchain. These tokens certify the authenticity, uniqueness and

participants to interact immediately with sellers. A format already popular

ownership of a digital object.

in China and registering record sales.

The success and novelty of NFTs have contributed to creating speculation,

Mobile apps have become an established business

which in some cases is putting this technology in a bad light, even though it could actually prove to be very interesting and full of potential.

Data from App Annie tells us that the typical mobile user spends an

With the hope that, after the initial irrational phase, the conversation will

average of 4 hours and 48 minutes a day using their smartphone.

focus more on creating effective and lasting value, in this context, brands

Smartphone users around the world spent a total of $ 170 billion on apps

can start thinking about how to draw on these digital resources, creating

and in-app purchases in 2021.

their own NFTs or building partnerships with creators that allow you to

Therefore, the app business (and in-app purchases) presents an

build a real community and provide added value for your customers.

important opportunity for brands, which can take advantage of this might think, users are willing to pay for access to an app they find useful.

Cryptocurrencies will be the future (but only for certain demographic groups)

However, as always in marketing, the key to success lies in the usefulness

Another asset that is attracting people’s attention like NFTs are

of what we offer. Otherwise, the risk is to invest in something that will give

cryptocurrencies, on which the debate is often polarized, perhaps

no added value to our audience and no return to our brand.

because this time around as well, speculation has put the technology in

format to offer their products and services. And, contrary to what one

NFTs towards the creation of a lasting value NFT stands for non-fungible tokens, i.e., unique digital assets such as

a bad light, even if more and more people use it: the number of people owning cryptocurrencies increased by over a third (+ 37.8%) compared to last year.

18-21/5/2022

UCIMU-SISTEMI PER PRODURRE

065/2019

LMRX19RS1

GWI reports that more than 1 in 10 users

countries, accepting cryptocurrencies could

been owned by Facebook, Instagram, Twitter

now owns some form of cryptocurrency,

help attract new customers.

or any other platform. We, as a brand, have no

a figure that rises to more than 2 in 10 in

direct control over that audience.

developing economies – where conventional

The transition to first-entry data is getting closer and closer

currencies are more subjected to exchange

For two years now, we have been talking on the

Translated into practice, this means that

rates fluctuations – that cryptocurrencies are

one hand about the growing concern about

brands need to start integrating data collection

becoming more widespread.

data privacy and on the other, about the end of

methods that put consumer privacy first. How?

Therefore, digital currencies offer a potential

third-party cookies.

By investing in campaigns aimed at collecting

that has not yet been explored: if in a country

In reality, the privacy discourse highlighted a

proprietary data through e-mails, newsletters,

like the United States they are used by a

problem that we already knew but to which we

social media and CRM.

niche of users, in other countries they are

have probably never paid too much attention:

It may seem to some that we are regressing

more widespread. If our audience is in those

what we call “our audience” has actually always

compared to where we are today. But it is not

Thailand. Indeed, it is precisely in countries with

This is why experts identify 2022 as the year we should actually start owning our audience.

only the success of our marketing strategy that asks this from us but – obviously – our own audience as well.

Summing up Thanks to the spread of digitalization, the increase in connection speed, as well as the greater accessibility to increasingly powerful digital tools, the digital world is moving rapidly towards increasingly immersive experiences and new, more engaging formats, able to draw the best from social media and entertainment. Brands that want to stand out in this scenario will have to be able to keep up with the times, quickly abandoning the initial distrust of new technologies and instead thinking about how to present the brand.

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EXPO DELLA TECNOLOGIA CUSTOMIZED PER L’INDUSTRIA DELL’ALLUMINIO, DELLA FONDERIA E DEI METALLI INNOVATIVI

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STANDARD & LEGISLATION - UCIF Informs

Surface Treatments: The Technological Requirements of the Market Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

he challenges of this century see humankind in a close

information and of any deviations from the set standard in order to

relationship with technology, in which speed and precision in the

take corrective action; and the development of a remote service with

execution of tasks by automated solutions are crucial. Still, it is

predictive maintenance and remote assistance actions.

only human intervention that makes the industrial production process

Surface perfection and coating quality are now two of the excellence

unique though ingenuity. In fact, even the most advanced machine

factors sought in products, such as design, reliability, and functionality.

cannot make an industrial process complete and competitive, or

Every day, the industry is confronted with issues concerning shapes,

automate and digitalise it, without the intervention of people, with their

surfaces, materials, and design on the one hand and productivity, cost

knowledge and skills. For most manufacturing companies, the use of

optimisation, the environment, innovative technologies, and safety on

automation is a necessary step to increase productivity, reduce costs,

the other hand. This contributes to a technological vision that integrates

and improve competitiveness.

into production processes where excellent surface finishes are required

In addition to this, the market is clearly moving towards the increasing

as well as coatings with high protective and anti-corrosion performance.

customisation of the products offered. This calls for increasingly flexible

In the era of interconnectedness, global competition, and just-in-time

and adaptive production processes, in which digitalisation and the

production, the industry can only remain competitive if it continuously

use of artificial intelligence for monitoring and predicting equipment

innovates. The surface painting and coating process is certainly complex

conditions are more and more important. A modern concept, therefore,

and articulated, due to the large number of variables that characterise

should integrate an increasing number of interconnected modular

it. Thanks to innovation across all products/solutions, however, unit

systems, such as, for example, AGVs for internal logistics and the robotic

production costs can be reduced while increasing efficiency. The goal

arm technology for coating. It should also be associated with other

is to meet emerging key market demands such as environmental

aspects that have become fundamental for industrialising a Smart

friendliness and safety in the working environment; reduction of

Factory, including the design and integration of smart AGV systems for

processing costs; high finishing quality; Industry 4.0 and digitalisation of

intralogistics, capable of optimising flows and batches of parts to be

products and systems; and robotic painting systems that guarantee high

painted with increased safety; the design of coating systems managed

productivity, consistent quality, and greater production flexibility.

according to concepts of flexibility, modularity, and digitalisation, with

The new, innovative dynamics of markets and of the industrial coating

control logics and integrated automation solutions linked to robotic

sector are leading Italian companies towards a new technological level

stations; the optimisation of surface finishing operations, where the

capable of meeting the standards of the most ambitious processes.

management of the various products and processes is entrusted

UCIF is proud to represent this Italian industry, which also stands out on

to specific automation; monitoring of productivity/consumption

the European and world stage.

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The S.M.A.R.T. Conference Organised by UCIF Reached its Second Edition The second edition of UCIF’s S.M.A.R.T. conference will be held in Milan on 18 May 2022, focusing on the theme of technological innovations in surface finishing aimed at improving environmental sustainability and boosting production.

rganised by the Italian Surface Treatment Equipment

important evolution especially in terms of sustainability of material

Manufacturers’ Association (UCIF), a member of the

processing operations with a view to reducing consumption,

Confindustria ANIMA association, and sponsored by the City

optimising management, and complying with environmental protection

of Milan and PoliEFUN, the second edition of the S.M.A.R.T. conference

regulations.

(an acronym for Surface, Manufacturing, Advanced, Research, Trends)

UCIF President Daryush Arabnia described the S.M.A.R.T. Conference

will take place at the Fondazione Cariplo premises in Milan on 18 May

as “an important event that will act as a driving force for our sector: its

2022.

aim is to describe the technologies and the evolutions achieved by the

Following the success of the previous event, this new edition of the

Italian finishing industry and its efforts towards important goals such

conference will focus on technological innovations in surface finishing

as respect for the environment, sustainable development, the circular

aimed at improving environmental sustainability and boosting

economy, and the focus on Italian-made products.”

production in Italy. In fact, the finishing sector plays a strategic role of processes: every product requires a surface treatment, be it

Innovation and case studies presented by their protagonists

deburring, cleaning, shot blasting, anti-corrosion treatment, coating,

The topics discussed at the S.M.A.R.T. conference will cover all areas

or chrome plating. In the last few years, it has been undergoing an

of the surface treatment world, such as washing and cleaning after

in the Italian manufacturing industry, as it is present in the majority

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ZOOM ON EVENTS

machining, pre-treatment and subsequent powder and liquid coating

• Smart solutions and software for planning production batches in the

processes, and relevant software solutions. The application fields will

mass coating of small parts.

range from automotive and commercial vehicle components to small

• Further speeches and details will be announced by UCIF in the weeks

metal parts.

leading up to the event.

Nine talks are currently confirmed for the conference, which will be in the industrial finishing sector, such as Fismet, Rösler Italiana, Verind,

A growing sector offering numerous business opportunities

Geico, SAT, IMEL, Pangborn Europe, and PoliEFUN. Alessia Venturi,

Participating companies will not only be able to present to the public the

the editor-in-chief of the ipcm® magazines, will also be present at the

technologies they have developed with a view to greater sustainability,

conference as a speaker.

but they will also find in this event an ideal opportunity to improve

The covered topics will include as follows:

cooperation among various players in this fast-growing sector. “After the

• The circular economy as a way of optimising the costs and

2020 crisis caused by the Covid-19 pandemic, the finishing equipment

management of raw materials and reducing the environmental impact

industry has seen an encouraging recovery, with a total turnover of 780

of production.

million Euros according to estimates by Ufficio Studi ANIMA and a +7.6%

• Innovations and examples of real applications of waste water

growth, exceeding even 2019 values,” Arabnia has stated.

centrifugal recirculation systems to remove pollutants.

At the end of the S.M.A.R.T. Conference, UCIF will also offer the chance

• Digitalisation and Artificial Intelligence applied to improve surface

to take part in a social programme that will include an outdoor theatrical

finishing processes in the automotive sector.

visit of the Brera district, lasting about an hour and performed by

• Machine Learning and predictive maintenance software as a tool

professional actors, as well as an aperitif at Granaio Duomo, in via

to reduce the energy consumption needed to paint automotive

Tommaso Grossi 3, in order to offer a networking opportunity for all the

components by 70%.

participants in the conference, including the speakers.

given by experts and representatives of the main companies operating

• The evolution and future of vertical coating systems. • The new frontiers of chemical pre-treatment prior to coating to increase surface protection for a more sustainable development.

For further information: www.ucif.net

UCIF Established in 1973 as a member of the Confindustria ANIMA association, the Surface Treatment Equipment Manufacturers’ Association (UCIF) represents over 50% of the Italian producers of machines and plants for surface treatments (coating, cleaning, shot blasting, air/water purification, handling, automation, and robotic systems). It has always been a part of ANIMA, which represents the Italian mechanics industry within the Confindustria association. UCIF, in particular, represents a sector that boasts over 2,050 employees, an annual turnover exceeding 780 million Euros, and an export share of about 69%. Its relation with ANIMA gives it international visibility, the chance to participate in the round tables, and greater collective strength.

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Coatings For Africa Returns as South Africa’s Construction Sector Gets Set for Revival Coatings For Africa will be held at the Sandton Convention Centre, Johannesburg (South Africa), on May 4-6, 2022.

ollowing on from a tough period for industry in South Africa,

continent. Producing around 324,000 litres of paint per year with a

Coatings For Africa is returning on May 4-6, 2022 at the Sandton

value of approximately US$947M, the country’s paint industry is home

Convention Centre in Johannesburg (South Africa), for a three day

to more than 300 coatings manufacturers and is dominated by the

exhibition, conference and networking event that will take advantage

decorative paint segment, as well as being an attractive market for the

of the recent surge in construction activity and government investment

automotive and architectural coatings industries.

throughout the country. With a rich history of success through its association with the Oil

The largest coatings event in Africa

and Colour Chemists’ Association (OCCA) and South African Paint

Coatings For Africa is the largest dedicated coatings event in Africa for

Manufacturing Association (SAPMA), this ‘live and in person’ event will

raw material and service suppliers, equipment and paint manufacturers.

provide a forum for exhibitors and visitors to meet global buyers and

The event creates the perfect environment for manufacturers, raw

suppliers at Africa’s leading event for the coatings industry.

materials suppliers, distributors, buyers and technical specialists like

Interest in Africa’s emerging coatings markets is well-established and

formulators from the coatings industry to meet face-to-face. The event

South Africa is among the largest and most influential markets on the

also offers the opportunity to gather insight on the latest processes,

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exchange ideas with industry leaders and build a strong network in the

and water. Amongst all this activity, the opportunities and potential for

African continent.

the coatings industry is abundant. Following on from the difficult period

The last Coatings For Africa event, held in 2018, attracted more than

caused by COVID-19, now is the perfect time for manufacturers and

250 exhibitors from 18 countries, with more than 2500 attendees.

suppliers to the coatings industry to take advantage of the proposed

Of these, 80% of exhibiting companies said they would recommend

government investments and the surge in construction activity and get

Coatings For Africa as an important, positive and profitable event.

back to business.

Building opportunity

Creating sustainable solutions

Decorative paint manufacturing and sales account for approximately

One particular area of focus for industry in South Africa is

80% of South Africa’s coatings market, with major players and brands

environmentally sustainable technology. The government, for example,

including Kansai Plascon Africa and ICI Dulux. Intrinsically linked,

has pledged to produce 26% of the country’s total electricity from

therefore, with activity in the construction industry, the outlook for

renewable energy sources by 2030. To achieve this, the state-owned

South Africa’s coatings industry is bright: the country’s construction

electricity public utility company Eskom plans to invest ZAR106 billion

industry is expected to have grown up by 4.6% in 2021 and register an

(US$6.6 billion) on the construction of wind farms and solar plants until

annual average growth of 4.1% between 2022-2025.

2030 – providing a market for high performance, protective coatings.

This positive surge follows on from a steep decline during the

The paint industry in South Africa also continues to increase its expertise

COVID-19 pandemic and will be supported by investments on

and focus on other environmental issues, such as the reduction of lead

transport, energy, residential, water, health and education projects.

in paint and improved manufacturing processes to reduce VOCs. At

In the latest government budget, unveiled in February 2021,

this innovative time in one of Africa’s leading coatings markets, Coatings

ZAR791.2 billion (US$49 billion) was allocated towards public-sector

For Africa is the perfect platform at which to integrate your company

infrastructure spending and hence, the construction industry, from

and products into this thriving market. As well as the exhibition, the

2021-2024. Of this, ZAR287 billion (US$17.8 billion) was budgeted

conference will provide a chance to learn about the latest innovations

towards the transport and logistics sector; ZAR149.9 billion (US$9.3

and developments from leaders in the industry.

billion) towards the energy sector; and ZAR120 billion (US$7.4 billion)

The Coatings For Africa exhibition and conference is co-hosted by The

towards the water and sanitation sector, among others.

Oil & Colour Chemists’ Association (OCCA) and the South African Paint

This investment in infrastructure has attracted support from the World

Manufacturers Association (SAPMA), ensuring that you will be able to

Bank and Development Bank of South Africa and in the longer term,

meet the key decision-makers in this industry.

the construction industry’s output will be supported by a 10-year ZAR2.2 trillion (US$133 billion) infrastructure plan, comprising 276 projects across various sectors, including transport, energy, housing

For further information: www.coatingsforafrica.com

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SFCHINA2021 Physical Show Now Cancelled – Visit the Show Online Until March 15 The SFCHINA2021 Shanghai physical show has been cancelled, and the 2021 exhibition continued to be staged online.

o cope with latest requirements from the Shanghai Government

Save the 2022 Guangzhou Show Date

on epidemic prevention and control, and to safeguard the health

After rebounding to an estimated 5.5% in 2021, global economy is

and safety of exhibitors and visitors alike, coupled with the fact

expected to grow by 4.1% in 2022 while the Asia Pacific economy is

that Shanghai Government has suspended license application for

forecast to return to world-leading growth of 4.5%. China’s economy

large-scaled gatherings (including exhibitions), the organizers have

is anticipated to expand 4.3% this year. The Greater Bay Area (GBA)

announced on January 19 that SFCHINA2021 physical edition was

is China’s major development strategy. Continued investment

officially cancelled.

drives development of various infrastructures in the GBA, building a

Continue to be held online

brighter future for the surface finishing industry. SFCHINA has been collaborating with the industry to move forward since 1983. Our 2020

The 2021 exhibition continued to be staged online at

Guangzhou edition attracted over 4,000 trade visitors and over 160

www.sfchinaonline.net, which was live and stayed open until March

exhibitors. SFCHINA2022 will be held on December 6-8 in Guangzhou,

15, where visitors were able to continue visiting over 190 exhibitors

P.R. China at Area A of China Import and Export Fair Complex.

online. From March 2 onwards (original opening date of the physical show), visitors were able also to watch live or pre-recorded videos such as editor’s recommendations and featured videos prepared by industry experts, professors and exhibitors, etc. Registered visitors of the physical show have received an email to login to the online show

For further information:

directly, without having to go through the registration process.

www.sfchina.net and www.sfchinaonline.net

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ZOOM ON EVENTS

Next June METEF 2022 will Come Back to Bologna METEF, the international fair for aluminium, foundry and innovative metals industry, returns from 9-11 June to BolognaFiere, simultaneously with MECSPE.

rom automotive to electronics, from transport to mechanical

Like the Aluminium Extrusion Forum, the focus on the use of aluminium

processing, up to the construction industry, over the last

extrusions in various sectors, from construction to mechanics and

decades aluminium is more and more used in everyday life and in

transport. The Light Alloys Castings Foundry Conference will deal with

the industrial field.

the current framework and prospects of the aluminium castings foundry

A sector with “infinite” end use applications, which in 2021, just for the first

through the analysis of the drivers of the industrial, university and

productions and transformations in Italy is worth a turnover of 12 billion

institutional scenario. Looking at the end uses, the automotive sector is

euros (+30% on 2020), employing more than 15 thousand people1, and

of primary importance for aluminium and its alloys, the topic will be the

that for the whole chain, including final uses, counts a turnover of more

focus of the Aluminium and Cars Conference during which the latest news

than 40 billion euros . A sector that will play a strategic role in the pursuit

on materials, technologies and applications will be presented against

of international industrial decarbonisation goals.

the issues relating to lightening, the availability of raw materials and the

Aluminium, in fact, besides being cheap, light and flexible, can be recycled

relevant regulations.

and reused indefinitely in production processes, with extraordinary

Aluminium is considered the “metal of the future” in terms of

positive effects in terms of circular economy and energy saving. This

technological flexibility, circular economy and eco-sustainability, all aspects

is done definitely in order to take advantage of the new challenges

that will be the focus of the Green Aluminium Conference, an event that

and opportunities in the sector that METEF, the international fair for

will take place in Bologna with its second stage, in which the main qualities

aluminium, foundry and die-casting, transformation, processing, finishing

of eco-sustainable aluminium, both primary and secondary production,

and end-use industries, will be returning to BolognaFiere from 9 to 11

will be presented.

June 2022. The event, now organized by Senaf, will be held at the same

Finally, to highlight the work of the key players in the sector,

time as MECSPE, the most important event dedicated to innovations for

the METEF Innovation Award will return in 2022, an international initiative

the manufacturing industry.

which aims to reward the most innovative case histories submitted by

“METEF returns to focus on its role as a national and international driving

enterprises, related to innovation in plants, technologies, products and

force to assist SME in the aluminium sector, which make up about 95%

applications in aluminium and its alloys. A special prize will also be

of the workforce and over 70% of the turnover of the industry in the

awarded to projects aimed at decarbonizing the company system as a

European Union – says Mario Conserva, President of METEF – From

whole.

Bologna, the new edition of METEF will be projected onto the international scenario and will have to bring together all the players in the supply chain, both national and international, to set up the priorities of this sector. And it will do so by being able to count on the concomitance with the main exhibition for the manufacturing industry, MECSPE, which for years has been a reference point for entrepreneurs who want to innovate production processes.” For 25 years, METEF has been highlighting the main developments in the international light metal industry through a busy program of conferences, events, special initiatives and demonstration activities.

1 2

Source: CentroAl Source: A&L – Alluminio e Leghe Magazine

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For further information: www.metef.com

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LAMIERA 2022 Moved Up One Week to 18-21 May 2022 in Milan LAMIERA 2022, the international exhibition dedicated to the industry of sheet-metal forming machine tools and innovative technologies related to the sector, will take place one week earlier: the event is thus scheduled at fieramilano Rho from 18 to 21 May 2022. © Lamiera

scheduled for the month of May and, with its over 200 already collected applications to exhibit, intends to repeat the success of the two previous editions hosted in Rho-Milan. “In agreement with fieramilano – stated Alfredo Mariotti, general manager of UCIMU-SISTEMI PER PRODURRE – given the importance of the event, we thought it necessary to maintain the trade show in the same period, i.e. in the second half of May. Considering the rapid return to normal standards that we are experiencing over the last few weeks, the increasingly extensive vaccinations and the experience we have acquired during two years of pandemic, we know that LAMIERA will be held in a period that can be considered safe with regard to the public health emergency”. “We should not forget that, while organising numerous events in the Covid period, our staff and that of fieramilano have now gained a long-standing experience in the field to define safety standards and

procedures to be adopted, in order to enable a comfortable and safe

that have imposed a postponement of all events scheduled for the first

promotion by us the organisers with all the public concerned: exhibitors,

quarter of the current year.

visitors, journalists. We are very pleased to make this investment, feeling

Events taking place in the months of May and June, which had not

sure that our activity will allow to minimise, or even completely eliminate

been scheduled before, also occupying large exhibition spaces and

any possible inconvenience for the operators involved. The exhibiting

requiring very long setting-up times, have compelled fieramilano to ask

companies of LAMIERA will be offered a trade show rich in content and

all the involved organising bodies to arrange new “date combinations”,

ideas, which will thus attract lots of visitors”.

in order to ensure that all exhibitions in the new agenda can be held

“After all – concluded Alfredo Mariotti – this choice to meet the

properly.

requirements of the host exhibition centre and of the organisers of

Therefore, LAMIERA will take place seven days earlier than its scheduled

other trade shows gives credit to the industry represented at LAMIERA,

date to guarantee appropriate organisation times for exhibitors

as one of those which, while understanding the problems caused by

participating in the event. LAMIERA will be followed by the Milan

the public health crisis for the sector of trade fairs, contribute to its

Furniture Fair (Salone del Mobile), which will be held in June and will

relaunch and development, aware of the crucial and irreplaceable role

also have very long setting-up times.

of exhibitions in supporting the business activity of manufacturing

Promoted by UCIMU-SISTEMI PER PRODURRE, the Italian machine

enterprises”.

he exhibition has been moved up due to a necessary

stay within the exhibition centre”.

reorganisation in the calendar of the trade fairs held at

“The decision to bring LAMIERA forward by one week - added Alfredo

fieramilano, as a consequence of the public health conditions

Mariotti – implies a big investment in terms of communication and

tools, robots and automation systems manufacturers’ association, and organised by CEU-CENTRO ESPOSIZIONI UCIMU, LAMIERA is however

For further information: www.lamiera.net

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Powder Coating Week 2022 The latest Powder Coating Week’s edition took place in Orlando (FL, United States) from 7 to 9 March 2022, and explored the most topical subjects of the powder coating industry.

C Week is Powder Coating Institute’s

Most presentations at the conference dealt

stability is possible if the material is limited

annual get-together and was held

with some aspect of how to manage a powder

to a maximum of 22°C. This has economic

in Orlando outside of the SeaWorld

coating finishing operation. Such riveting

ramifications on transport, storage and

complex at the Renaissance hotel. The week

topics as how to ground (earth) parts, spray

application conditions.

kicked off with a Custom Coater Forum

gun settings, installing a manual batch powder

Another interesting presentation was given

where job coaters assembled to hear experts

system, and preventative maintenance tips

by Bob Kelly of PPG. He provided a detailed

provide suggestions on how to get control

and tricks.

treatise on the performance of a FEVE

of your business, techniques to access your

A couple talks offered recent advancements

(fluoro-ethylene vinyl ether) based powder

government representatives, differentiating

in powder materials technology. Of note was

coating capable of meeting AAMA 2605 (10

your business, job scheduling techniques,

Cal Ezeagu’s (Allnex) talk on ultra-low bake

years Florida) requirements. This particular

and approaches to employee training.

powder breakthroughs. Ezeagu presented

chemistry not only exceeds this performance

Concurrently classes were held to teach the

thermosetting chemistry options for sub

criteria but also provides excellent transfer

basics of spraying and curing powder coatings.

150°C temperature cure. He explained the

efficiency with low volatiles of cure.

The conference portion had a diverse

pros and cons of using hybrid and polyester

PC Week also included a very well attended

array of speakers anchored by an insightful

(TGIC, HAA and PT-910 types) powders for

table-top exhibit featuring a vast array of

keynote by Chris Miller of Arkema. His theme

application to interior non-metallic substrates

powder coating producers, raw material

was “Sustainability in the Powder Coating

such as MDF and natural wood. Allnex’s

producers, and both application and

Industry”. The concept of sustainability can be

latest developments yield a hybrid (epoxy-

curing equipment engineers. It was a good

open to interpretation and Miller began his

polyester) system that provides excellent

opportunity to reconnect with industry

presentation with results of surveys Arkema

smoothness and chemical resistance at 130°C

colleagues that had been previously

had conducted with industry colleagues

cure temperature. He advocates the use of

constrained due to the pandemic.

regarding their understanding of sustainability.

gas catalytic infrared as the primary source

Not surprisingly the responses concluded that

of heating the coating. One big caveat was

“Sustainability is a major trend, consumers

added, however. The powder coating requires

For further information:

won’t pay for it and, (most importantly), no

rather careful handling. Physical powder

https://conference.powdercoating.org

one knows what it means.” I have been waiting for an honest assessment of this driving movement and the survey results did not lie. Nevertheless, Miller outlined how sustainability is a goal of corporate responsibility and defined it as meeting the needs of the present without compromising the ability of future generations to meet their own needs. He went on the break down the individual aspects of sustainability as: responsible sourcing, climate & environment, safety, diversity, community and innovation on sustainable products. He wrapped up the keynote with examples of how Arkema is tackling each one of these objectives. © PCI

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SANDTON CONVENTION CENTRE JOHANNESBURG, SOUTH AFRICA

CONNECTING THE COATINGS INDUSTRY IN AFRICA Meet global buyers and suppliers at Africa’s only trade event for the coatings industry

2,500+ attendees

8,000+ Sqm

TO BOOK A STAND, CONTACT US: #COATINGSFORAFRICA www.coatingsforafrica.com

250+ exhibiting brands

exhibiting countries

Andy Gathercole, Senior Sales Manager T: +971 4 445 3712 | M: +971 56 990 7089 E: andrewgathercole@dmgevents.com

Organised by

ZOOM ON EVENTS

Finding a Balance Between Energy Supply Security and Climate Change HANNOVER MESSE 2022 will take place from 30 May to 2 June at the Hannover Exhibition Center (Hanover, Germany).

he world is experiencing a turning point

“In view of the current global political situation,

as roughly 100 startups that find HANNOVER

in international economic and energy

the topics at HANNOVER MESSE are more

MESSE an ideal platform for networking with

policy – one that brings with it rising

relevant than ever,” reported Dr. Jochen

industry.

energy prices, disrupted supply chains and a

Köckler, CEO of Deutsche Messe, at the

major impact on global industrial production.

HANNOVER MESSE preview event. “At the

At the same time, a growing number of

heart of the matter is how we can ensure

manufacturers are doing their part to combat

security of supply and growth in a dynamically

Green energies and hydrogen – driving supply security and climate protection

climate change. The world needs speedy

changing world – politically, environmentally

solutions in this area: political, economic and

and economically – while counteracting climate

When it comes to CO2-neutral production and

technological. HANNOVER MESSE 2022 is the

change. Innovative technologies will play a key

and green hydrogen play a key role. Many

ideal setting.

role in this,” he added.

companies already lead the way with concrete

From 30 May to 2 June, some 2,500 companies

Exhibiting companies include corporations

solutions. For example, HANNOVER MESSE

display their technologies for the factories and

like Siemens, Bosch, Schneider Electric,

exhibitor Bosch created a hydrogen cycle at

energy systems of the future at the Hannover

Schaeffler, Microsoft, SAP and Service Now,

its Industrie 4.0 facility that produces green

Exhibition Center. Under the lead theme of

joined by numerous medium-sized industrial

hydrogen for industrial processes.

“Industrial Transformation”, they demonstrate

enterprises such as Beckhoff, Festo, Harting,

Because of the current energy supply debate,

how connected production facilities can

Pepperl+Fuchs, Phoenix Contact, Wago and

the topic of hydrogen is gaining further

operate more efficiently and conserve

Ziehl-Abegg. Accompanying them are major

importance at HANNOVER MESSE. “We have

resources as well as how to generate and

research institutes like Fraunhofer and

offered the largest European platform for

transmit energy sustainably.

Karlsruhe Institute for Technology (KIT) as well

the hydrogen and fuel cell industry for years.

energy security in Europe, renewable energies

In Hannover, more than 200 companies – including Iberdrola, Saint Gobain, Emerson, ElringKlinger, Plug Power, Siemens, Phoenix Contact, Enapter, Bosch, Hexagon Purus, Nel Hydrogen, Hydrogenious and GP Joule – present solutions for a sustainable energy supply based on hydrogen derived from renewable energy sources,” said Köckler.

Using digitalization, automation and AI to help combat climate change Europe is striving to become climate-neutral by the middle of the millennium. More and more companies have set ambitious goals and are in the process of completely converting their production and services. HANNOVER MESSE exhibitors supply the necessary technologies. © Deutsche Messe

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Not only can the production of virtually all

ZOOM ON EVENTS

goods be made more resource-conserving and

Prime Minister António Costa will jointly open

looking to Hannover. This year in particular,

energy-efficient with the help of state-of-the-art

HANNOVER MESSE. This year, Portugal is

HANNOVER MESSE 2022 can send economic

machinery and equipment, but solutions from

the Partner Country of the world’s foremost

policy signals and build bridges.”

mechanical and plant engineering, electrical

industrial trade fair.

In addition to the exhibits at the show,

engineering, and the software and IT industry

More than 120 companies from Partner

attendees can look forward to a first-rate

can also vastly improve the control processes of

Country Portugal have registered for

supporting program. The four conference

complex systems, thus boosting innovation and

HANNOVER MESSE 2022. Under the motto

stages cover topics like automation, cloud

reducing greenhouse gas emissions around the

“Portugal Makes Sense”, they present

and infrastructure, analytics and data

world.

their products and solutions for digital

management, digital platforms, robotics,

Recording the CO2 footprint across entire

transformation, the energy transition and

IT security, artificial intelligence, renewable

supply chains is often the first step towards

reliable supply chains.

energies, green hydrogen, energy-efficient

climate neutrality. HANNOVER MESSE exhibitor

Other political dignitaries, such as Frans

Siemens has developed software that captures

Timmermanns, Vice President of the European

management, the circular economy and much

emissions data along the supply chain and

Commission, and Bettina Stark-Watzinger,

more. The complete program will not only be

combines this with data from the company’s

Federal Minister of Education and Research,

available to visitors on-site, but will also stream

own value chain to determine a product’s actual

have also confirmed their attendance. This

simultaneously via the HANNOVER MESSE

carbon footprint.

means that after a two-year “coronavirus

website.

Economic policy platform plus Partner Country Portugal German Chancellor Olaf Scholz and Portugal’s

and CO2-neutral production, digital energy

break”, HANNOVER MESSE once again provides an international stage for economic policy discourse. According to Köckler, “At the end of

For further information:

May, the global industrial community will be

www.hannovermesse.de/en

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EDITORIAL BOARD Prof. Massimiliano Bestetti:

Kevin Biller

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics

The Powder Coating Research Group

Dr. Franco Busato: European environmental legislation and new technologies

Material Engineering and Industrial Technologies, University of Trento - Product Design

Prof. Paolo Gronchi:

Dr. Fulvio Zocco:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section

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