Painting
In the field of industrial coating, resource-efficient processes have long been at the forefront. Efforts to make processes more efficient range from electrostatic coating to powder coating and UV coating. Last but not least, exhaust air treatment is also an important topic.
Towards Zero Emissions: BMW Advances Sustainable Manufacturing at its Debrecen Plant
BMW arbeitet systematisch daran, seine Fertigung und insbesondere die Oberflächentechnik CO₂-neutral zu machen. Erfahrungen aus vielen Standorten fließen nun in das Werk Debrecen ein, das mit dem Serienanlauf der Neuen Klasse im September eine neue Ära nachhaltiger Automobilproduktion einläutet.
Increasing production with dry deposition
Mittels einer Umrüstung auf ein neues Trockenabscheidungssystem mit Farbnebelabscheider und neuem Nachfilterelement ließ sich bei Liebherr Hausgeräte in Lienz die Standzeit der Filter versechsfachen. Sowohl die Wirtschaftlichkeit als auch die Nachhaltigkeit sowie die Ergonomie des Lackierprozesses verbesserten sich deutlich.
A new approach to wing painting
Die Lackierung von Flugzeugen unterliegt hohen Anforderungen an Performance und Funktionalitäten. Bisher waren deshalb bei der Lackierung der Flügel zwei unterschiedliche Lacksysteme für deren Ober- und Unterseite notwendig. Ein Lackhersteller hat jetzt ein System entwickelt, mit dem man beide Seiten beschichten kann.
Paint line to success
Anyone offering variety must be able to produce in the shortest possible time and in the most diverse quantities. Cost, quality and flexibility in the production process were the decisive factors for a Swiss company to carry out the surface treatment in-house using a modern door painting line.
CO2-neutral painting
FabriCar in Bad Aibling consistently relies on renewable energy and a holistic consumption and supply concept that makes CO2 neutrality possible even for energy-intensive companies.
New base coat line in Neckarsulm
Es gab guten Grund zu feiern bei der Eröffnung der neuen Grundlacklinie bei Audi in Neckarsulm: In der neu gebauten Halle kommen Technologien zum Einsatz, die den Standort Neckarsulm deutlich effizienter und somit fit für die Zukunft machen.
Completely absorbed - in the soil
Jedes Jahr gelangen unzählige Eislöffel aus Kunststoff nach dem Gebrauch unkontrolliert in die Umwelt. Ein Hersteller von Spritzgussprodukten stellt solche Produkte nun aus einem biologisch abbaubaren Granulat her, das sich nach kurzer Zeit auflöst, sobald es mit Feuchtigkeit in Berührung kommt. Eine dünne Keramikschicht verhindert die Auflösung noch während der Nutzungsphase
21 percent less energy consumption
A new paint shop concept networks the energy flows for supplying all process steps and saves 19.2 percent of CO2 emissions over the entire life cycle - as well as 21 percent of energy in the utilization phase. It will be the first paint shop to meet the requirements of the EU taxonomy.
Awarded paint design
Only one car paint received the coveted Red Dot Award this year. The jury was won over by the technology and aesthetics of the paint, whose formulation is based on polymer structures.
Decision-making tool for investment
Climate impact to be expressed as a degree Celsius figure: a multi-award-winning climate tech company and a leading plant manufacturer are working on models to make the climate impact of paint shops for the automotive industry transparent and easy to understand.
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Anodic dip painting: integration for advanced users
Is it possible to integrate an anodic dip coating system into an existing powder coating system? And integrate a robot where space is at a premium? And implement everything during ongoing operation? A project shows what is possible.
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PSD 2024: 300 visitors and many current topics at the Powder Symposium
The powder symposium in Dresden opened the lecture season in the surface industry from February 8 to 9, 2024. According to the organizers, around 300 visitors and 180 users came to Dresden, and there were also many participants from Switzerland and Austria. The industry exhibition was also well booked with 50 exhibitors and was a popular point of contact for those interested in the individual topics, and not just during the breaks.
Self-healing through microcapsules in the paint
Self-healing surfaces sound like science fiction, but they are real. Fraunhofer scientists from polymer research provide insights into so-called active substances and their mode of action.
Volkswagen Commercial Vehicles achieves high coating quality with rotational dip coating system
Maximum flexibility is required, especially for the commercial vehicle sector. The new generation of the VarioShuttle rotational dip coating system enables model-specific rotation curves and guarantees a high coating quality for all body variants.
Car paintwork becomes sustainable and looks good
The automotive painting industry is undergoing a massive upheaval. In particular, the trend towards greater sustainability is prompting everyone involved to pursue new approaches. Wet-on-wet painting, bio-based paints and modern drying concepts are improving the CO2 balance. There is no need to compromise on special colours, wet looks or decorative elements.
Emil Frei: Ultra-high-solid paint for agricultural machinery
Agricultural machinery manufacturer Horsch relies on a new UHC system coating and achieves a significantly improved high-gloss finish. At the same time, fewer VOCs are emitted. The shorter drying times, which create additional capacity, are also an advantage.
Protection and styling for working horses
Whether the excavator is digging a fresh excavation pit or the tractor is ploughing a field - their field of application demands a lot from paints for agricultural and construction machinery. Added to this are the generally stricter environmental requirements. And last but not least, customers' visual demands on the coating are increasing.
Aabo-Ideal: Systems made in Denmark
AB Anlagenplanung GmbH, a company known for the design and implementation of customized coating systems, is taking over sales and consulting for the Aabo-Ideal Group in the DACH region as Aabo-Ideal GmbH.
Eisenmann back on course after three years
The renowned plant manufacturer Eisenmann GmbH finds its way back to profitable business after three years. Right at the beginning, investments in the further development and optimisation of proven products contributed to the successful restart.
Dürr: Large variety of colours in small quantities
In industrial automotive painting, paint supply systems for special colours with low production rates are more economical and sustainable than ring lines. They can significantly reduce paint losses, waste volumes and rinsing agent consumption.
BASF sets off for new shades
The mobility turnaround promotes new trends in automotive colours that differ from the classic colour spaces. In addition, the current Automotive Colour Trends "On Volude" features for the first time a colour developed together with an AI.
IAA: Consistent sustainable design
The "New Class" could represent the beginning of a design turnaround, because it is obvious that the mobility turnaround is not only leading to considerable technological upheavals in automobile manufacturing - the perception of the automobile is also changing.
DFO Automotive Conference: Important perspectives for the industry
The European Automotive & Plastic Coating Conference took place from 19 to 20 September in the Fanuc event rooms. A tight programme of 22 lectures on many current topics in the automotive sector was presented.
More degrees of freedom with Wagner automatic pistols
A new generation of automatic powder guns for coating systems as well as robot-based manufacturing environments, which has already won the Red Dot Award, offers several advantages over its predecessor.
Digital optimisation - the next level
Improve quality, reduce time: In Balgach, a new closed-loop control and the capabilities of current AI tools for parameter optimisation were demonstrated in practice.
Oltrogge: Reaching the goal with nitrogen
The use of nitrogen as an atomising gas in wet painting ensures particularly fine and efficient atomisation of the material, as is required in automotive painting, for example.
Braving the harsh environment in industry
Anyone who enters a production hall may quickly notice what a harsh industrial environment means: noise and vibrations, dust and aerosols in the air are perceptible and put a strain on the body. And the surfaces of the machines and tools also have to withstand a lot.
Wagner: On rails
At the site of the Bochumer Verein Verkehrstechnik (BVV), wheels for rail vehicles are forged and sometimes combined into complete wheelset systems. To meet the increasing demand, a highly efficient coating plant was installed in 2022.
Venjakob: More success through less "business as usual“
Automation and reduction of unit costs are high on the agenda in the wood and furniture industry for large series, but also for smaller companies in times of high costs for energy, materials and personnel. high on the agenda. Two application examples show how much can be gained through process modernisation.
![[Translate to English:] Profilometer Dr. Herrmann GmbH](/fileadmin/_processed_/2/4/csm_Aufmacher_Dr._Herrmann_e503f42228.jpg)
Dr. Herrmann GmbH: Systematically determining the influence of layer densities
A new measuring device led to the idea of a systematic analysis of the influence of film thickness on the formation of the surface of textured coatings - interesting insights were obtained.
Infrared camouflage with polyester powder coating
A leading paint manufacturer is developing special powder coatings that feature a highly effective camouflage function. The paints have been tested and approved by the Wehrwissenschaftliches Institut für Werk- und Betriebsstoffe.
passt coating: Perseverance and vision as a recipe for success
It doesn't always have to be a complete technological renovation involving a huge investment. A job shop that was almost liquidated in 2019 was able to start a new future under new management and with highly motivated employees. The basis for this was a comprehensive optimisation of processes and structures - but also two painting robots.
Powerful dip coating with rectifier from Dürr
A new rectifier for cathodic dip painting brings 50 per cent more power with the same space requirement. This makes it possible to design the layout of new plants more flexibly and to increase the capacity of existing plants more easily. The increased efficiency also saves operating costs.
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Dürr paint shop for Chery Mobile in China
The car manufacturer Chery Automobile Co. Ltd. is investing in a new turnkey paint shop for the flexible production of various models and drive systems. The focus is on intelligent networking and traceability of all process sequences. The commissioning of the plant in Wuhu, Chery's headquarters, is planned for 2023.
VdL: Paint industry under pressure
The German paint and printing ink industry is facing difficult times: High raw material costs, skyrocketing energy prices and bureaucracy are weighing on companies. On the other hand, consumers are cutting back on purchases, which is also affecting demand for coatings and inks.
Ford's departure into e-mobility
At Ford's main plant in Cologne, the switch to electric mobility and high energy costs are driving technological change. In addition to extensive modernisation in the area of application and cabin technology, quality control and digitalisation projects are also on the agenda - such as the 100 per cent colour control of car bodies using cobots.
For the eye and the wallet
Glück GmbH from Engen is a pioneer in aluminium bridge construction. The bridges are supplied with a sophisticated anti-graffiti protective finish using the wet paint process. This enables the company to meet the high demand for a durable and economical solution in the coating process as well.
60th company anniversary
Höcker Polytechnik has been developing, planning and producing extraction and filter systems for 60 years. With its focus on energy efficiency and compact solutions, the company has been able to make a name for itself in the wood and paper processing industry.
Creating space for design
Individualising stair construction: With an automatic coating system, a medium-sized joinery can now design stair treads as desired and also accept additional painting orders.
Coating under high voltage
A manufacturer of high-voltage equipment switched its coating of 12-metre-long aluminium pipes to HDLV technology. As a result, he was able to improve the surface quality and double his production capacity.
Amping up wind tower production
Demand in the wind energy sector is booming. To meet market demands, a construction company increased throughput in tower production with the help of a polyurea-based coating system. The particularly fast-drying polyaspartic system is applied in an airless or airmix process and processed directly.
More productivity for hydraulic cylinders
At KMF-Maschinenfabrik, hydraulic cylinders for agricultural and construction machinery were previously coated exclusively by hand. Extensive modernization has now led to significant improvements in quality and productivity.
Sustainably painted gas engines and more
Energy efficiency and sustainability are not only an issue of operating costs and productivity, but have long been a customer requirement. That is why an international manufacturer of gas engines and plant technology for gas processing and transport invested in a new start for its own surface technology.
Soft powder cloud for classy low gloss
A renowned household appliance manufacturer invested in a new powder coating system with dense phase powder conveying. In addition to a significant improvement in quality, an increase in flexibility and cost-effectiveness were achieved.
Clearcoat with irresistable effects
Fraunhofer IPA introduces stratifying effect pigments into the clear coat layer rather than the base coat layer. This allows new stylings to be created and the surface effect to be significantly increased.
Digitalized: from project planning all the way to maintenance
A fully automated painting plant in Neustadt an der Donau coats plastic components for automotive. Simulation techniques were used during project planning to eliminate future bottlenecks. A large number of smart sensors were installed for predictive maintenance and subsequent process improvements.
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Investing with an eye to the future
At the new site, a leading application technology manufacturer is building a new pilot plant with a highly flexible shuttle system. In the first construction phase, a pilot plant for wet paint systems was built and recently put into operation. An extension for powder coating
Choice made easier
A large-capacity paint booth with two zones was installed at an Austrian bulk materials technology specialist. The zones can be separated for modular painting of different colors in one batch, or combined into one zone for operation as a large-capacity painting booth.
Process development needs room to maneuver
A large competence center on 2,000 square meters creates ideal conditions for coating and process development for users from the wood and furniture industry. No matter what coating technology is required - Adler in Schwaz in Tyrol has the right plant technology.
Goodbye wetting disorders
Paint wetting impairment substances (LABS), such as silicones, oils or greases, cause ugly craters or streaks on freshly painted surfaces. They are very difficult to keep out of the painting process. SKF Economos Deutschland GmbH in particular has now found a way to keep LABS out of the painting process.
Competing sustainably
The bicycle is more popular than ever. The company Krüger Fahrrad- und Fahrradrahmenbau from Spenge-Wallenbrück also feels the significantly increased demand. The company handcrafts the backbone of every bicycle: the frame. These are coated using the wet or powder coating process - depending on customer requirements.
Structural change in the paint shop
In the past, there was no alternative in large-scale automotive production to having body shells enter the paint shop strung on a skid like a string of pearls and, after numerous stations, exit the paint shop in exactly the same order. Those days are long gone, however, and not only has the number of body variants multiplied since then, so has the customer's desire for individualization.
BMW: A new level of individualization
The second-generation application technology for overspray-free painting offers many new degrees of freedom in body design. Initial tests on a small series of the BMW M4 were positive - the series launch at the Bavarian car manufacturer is still scheduled for 2022.
Modular flexibility for more profitable processes
A large-volume cabin divided into several painting zones with intelligently controlled air ducts allows the Upper Austrian steel constructor M-Tron simultaneous and flexible painting and drying as well as a better energy balance. The Eham joinery was also able to sustainably improve its processes with the concept.
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Optimum grip when it counts
Achieving the prescribed slip resistance with hand-applied coating systems can be a challenge. Industrially applied UV coating systems, on the other hand, combine economy with reproducibility.
Bonded coating instead of grease
Wherever parts move, friction occurs and energy is lost. Bonded coatings not only reduce friction, they also protect against wear and corrosion. At the same time, ever stricter legal guidelines increase the requirements for approved lubricants and demand new technical solutions from manufacturers.
The new world of painting
A future-oriented layout is composed of flexible, intelligently networked process modules that can be scaled according to demand. Around these requirements, Dürr provided insights into the "paint shop of the future" and answers to the changes in the market in an elaborate live team event.
How paint drops get onto surfaces
In spray painting, the paint droplets have an impact speed of about 20 to 30 metres per second - surprisingly low when you consider how quickly they start at the atomiser. Fraunhofer IPA and Esslingen University of Applied Sciences are researching the underlying processes.
Color change in the automotive industry
The number of colour changes in the production lines of car manufacturers is increasing. Thousands of litres of paint are lost and high costs are incurred. With the right technology, however, this can be avoided.
Efficiency all along the line
Agricultural equipment that is permanently exposed to extreme conditions requires a particularly high level of corrosion protection. The Austrian company Brantner now relies on KTL coating and powder coating and also offers contract coating.
The right moment for a retrofit
A Dutch manufacturer of windows and door frames switches to robotic painting. Overall, the targeted upgrading of the painting line succeeded in reducing paint consumption by 50 per cent while doubling throughput.
New flexible atomizers
The Wagner Group supplements its range of high-speed rotary atomisers with special variants with external charging for the processing of water-based paints. They can be used for painting metal workpieces, automotive components and wood.
Economical and high quality in small series
Producing refrigerated and deep-freeze cabinets in stock was yesterday. The Spanish specialist for commercial refrigeration Frost-trol equips large chains in the food trade with brand-specific configured systems in the area of commercial refrigeration exactly according to customer requirements and commissioned a state-of-the-art production facility for this purpose.
Vehicle painting - as flexible as printing
Without the need to mask or unmask the body, a new painting technology allows individual paint jobs to be completed in a single pass. This can reduce turnaround times by 50 per cent.
VOC reduction also for existing plants
The emission limits for volatile organic compounds were tightened throughout the EU at the end of last year. This has consequences above all for existing paint shops. Dürr is working together with operators to develop action plans for VOC reduction.
Staying healthy while painting
The instructions in the safety data sheets are often neglected or even ignored. Where skin and eye protection are still implemented comparatively consistently, adequate protection of the respiratory tract is usually left out. The effects this can have are shown by the example of isocyanate.
Applying coatings with sharp edges - without any overspray at all
In almost every industrial sector, the number and diversity of workpieces that are coated is growing. In order to be able to paint the diverse components more efficiently than before, a new technical process has been developed that applies paints over large areas or in simple patterns with sharp-edged colour edges - and without any overspray.
Compact painting robot for industry
In the development of new special lacquers, WB Coatings came up against its limits with the hand application that had been customary up to then. This is why the globally active paint and lacquer manufacturer came up with an idea that was unusual in its industry.
Paint mist separation and water treatment sustainable and cost-optimized
In order to be able to operate a paint mist separation system in the most cost-optimised and sustainable way possible, paint shops have to take a number of requirements into account in order to select the optimum process for their operation: the dry or the wet scrubbing process.
UV coating: increase productivity, reduce emissions
Varnishes protect surfaces, give them new functions and refine them with special colours and haptics. UV varnishes, which score points for their environmentally friendly properties, are increasingly in demand: Since almost all their components react with each other through UV curing, virtually no VOC emissions are produced during their processing.
BASF: Modernized training center for refinish coatings
BASF Spain celebrated the official reopening of its modernised Refinish Competence Center at its site in Marchamalo (Guadalajara). From now on, technicians from paint shops, dealers and representatives of well-known automotive brands will be trained in the application of BASF's well-known premium brands Glasurit and R-M in the new training centre.
Trend colors 2019
Automotive Color Trends 2019/20, or ACT/9 for short, is the title of an analysis by BASF's Coatings division. In collaboration with four design studios from EMEA, North America and Asia-Pacific, BASF has analysed technological trends and social changes worldwide to draw colour inspiration for vehicle surfaces.
Overspray-free painting
The trend towards individualisation is also on the rise in car paint. For the automotive industry, the increasingly desired two-tone paint means considerable additional expense. Thanks to an innovation from Dürr, this is now changing.
Vehicle coatings cleverly dosed
At 300 dosing points, the central raw material supply of the dosing machines in the modern BASF Lean Lab is carried out by means of double diaphragm pumps. The pumps from Timmer play a significant role in process reliability in the laboratory.