PaintExpo 2024: Low-pollutant and resource-saving painting processes
Exhibitors at PaintExpo 2024 are thinking about how pollution in the paint industry can be reduced and how painting processes can be made more sustainable. At the same time, these should also run optimally in terms of economy and production technology.
Sustainability and efficiency are core topics at the upcoming edition of PaintExpo in Karlsruhe from April 9 to 12, 2024. In order to protect the environment and reduce the consumption of resources, paint suppliers, research institutions, manufacturers of process chemicals for metal and plastic coating and recycling companies, for example, will be thinking about how to reduce pollutant loads and how used materials can be sensibly recycled. In addition, PaintExpo exhibitors always take into account how to optimize painting processes in terms of economy and production technology.
Visitors to this year's PaintExpo will receive in-depth information on how pollutants can be reduced, resources saved and materials cleverly recycled at the stands of paint suppliers and exhibitors from research, the chemical industry and the recycling sector. The Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Gehold+Wiemer, Karl Bubenhofer, Kluthe, Nelco and Sherwin-Williams, for example, will be bringing new ideas for greater sustainability and efficiency in the painting process to the world's leading trade fair for industrial painting technology in Karlsruhe.
Reduce CO2 emissions, increase digitalization and automation
At the Fraunhofer Institute for Manufacturing Engineering and Automation IPA in Stuttgart, the Coating Systems and Painting Technology department researches ideas for increasing resource efficiency and sustainability and develops future-oriented solutions specifically for the paint processing industry. The current focus is on reducing the CO2 footprint. To this end, application-oriented research is being conducted into new forms of energy for painting processes, improving material efficiency, alternative material concepts and the optimal use of resources in the production process. Innovative, sustainable solutions are being developed for new and existing painting processes in order to master the current environmental and economic challenges together with painting companies.
The Fraunhofer IPA is also involved in simulation in order to implement new automation concepts quickly. This enables processes to be systematically optimized, more sustainable production to be implemented and improved economic efficiency to be achieved. One approach here is to increase the degree of automation in companies with a large variety of shapes and parts. To this end, tools are being developed that create a painting program directly in the simulation from given 3D models of components and products and, under the motto #simulate instead of try, eliminate the need for time-consuming teach-in on the robot. Under the three main themes of digitalization, sustainability and automation, Fraunhofer IPA will be presenting new processes, concepts and technologies at PaintExpo 2024, inspired by a bat, a crab and a drone.
Save energy with liquid and powder coatings
As system suppliers for powder coatings and liquid coatings, Geholit+Wiemer and Karl Bubenhofer traditionally present their latest innovations together at PaintExpo. In the field of liquid coatings, the focus is currently on high-solid coating materials with a solids-to-mass ratio of over 70 percent, which reduce energy consumption and save costs in production processes. The lower VOC content reduces consumption. Coupled with faster drying, high solids form the basis for an efficient coating process. In practice, many users have already switched to such systems and reduced their multi-layer to single-layer coating systems. In addition to complete work steps, drying times between the individual layers are also eliminated, resulting in immense time, energy and cost savings.
The selection of materials to improve the CO2 footprint also plays an important role in the powder sector. To this end, Karl Bubenhofer actively supports companies in switching to the Polyflex PES-165-NT-GU system. Above all, this achieves faster curing times, which reduces energy requirements. The fast-reacting polyester powder is suitable for outdoor use and has good degassing properties. Together with the appropriate primer, the powder can be easily processed without additional preparation. The bottom line is that the energy requirement is demonstrably reduced and costs are lowered. Kabe Farben has a large low-temperature range in many other areas and applications that generate high customer benefits.
Reduction of pollutant emissions in pre-treatment and in the paint store
The core elements of innovative new and further developments at Kluthe are sustainable raw materials, reduced consumption of chemicals and lower application temperatures in order to reduce energy requirements and the associated CO2 emissions for customers as far as possible. Kluthe's thin-film technology and low-temperature zinc phosphating not only save energy and CO2 emissions, but also conserve limited resources, reduce waste and cut costs. "Through continuous optimization, we reduce the consumption of scarce resources, increase energy efficiency and reduce CO2 and pollutant emissions, both for us and for our customers," says Stefan Lenzer, Head of Global Business Unit Pretreatment at Kluthe.
The resource-efficient Decorrdal thin-film technology will also be presented at PaintExpo 2024. It is the key to designing environmentally conscious and sustainable pretreatment. With products for the paintshop such as Cyclosol, a rinsing medium that is characterized by its efficient circulation and recycling options, Kluthe actively contributes to reducing waste and wasting resources. The sustainable Controx paint strippers are VOC-free and can be used sparingly, which contributes to a significant reduction in harmful emissions. In addition, Kluthe offers Nikutex, a water-based cleaning agent that is not only economical but also significantly reduces the environmental impact. Innovative sustainability tools are also used to calculate the environmental impact of customers' processes and offer advice on how emissions, waste and costs can be reduced at the same time.
Sustainable recycling of used powder
As an official specialist recycling company, the Belgian company Nelco recycles around 10,000 tons of used powder left over in filters and extraction systems from powder coating plants every year. "Our company is unique in Europe because we give the used powder a new lease of life and process it so that it can be reused as molded parts for the automotive or machine industry," explains CEO Arnd Nelde. After their second life, these molded parts can even be recycled again.
At the upcoming PaintExpo, Nelco will be presenting its sustainable and environmentally friendly process, which has been successfully operated for 22 years and is used by around 800 partner companies to dispose of used powder in an environmentally friendly manner. Research and development at Nelco has been driven forward in recent years. Using modern presses, new formulations and mixtures are being tested to expand the range of applications. "We are happy to take back all types of used powder. This includes fine dust, overspray, fresh powder, overstocked goods, residues and cyclone powder. These can include all common types such as epoxy powder, epoxy polyester, polyester, acrylic and PUR and can be provided in the original packaging, as a mixture or in a BigBag," says Arnd Nelde. At PaintExpo 2024, interested parties can find out from him and his experts how their used powder can be turned into sustainable components in the future.
Powder coatings made from plastic bottles and trend powder coatings Vision 2030
Sherwin-Williams will be showcasing an extraordinary innovation at PaintExpo 2024 with Powdura ECO powder coatings. This involves converting plastic bottles (post-consumer rPET) into a durable, high-performance polyester resin. Each kilogram of Powdura ECO coating contains the equivalent of 35 recycled plastic bottles and minimizes CO2 emissions by one kilogram. Powdura ECO offers the same properties as conventional polyester powder coatings. Powdura ECO coatings are suitable for indoor and outdoor use. They also offer increased flexibility and impact resistance as well as an excellent balance of mechanical properties, great color retention and solvent resistance. The coatings in this system can be adapted to all requirements and are suitable for third-party certifications such as Leed, Greenguard and Bifma Level.
Also on display will be the new Vision 2030 powder coating collection, which expresses the modern style of Syntha Pulvin in four inspiring color palettes. All 48 coatings meet the requirements profiles of the quality communities: GSB Florida 3 and Qualicoat Class 2. Inspired by nostalgia, the impact of technology on big cities, nature and community spirit, the colors evoke emotions, define global cultures and stimulate the imagination. (OM-3/24)
► Find out more about PaintExpo in our PaintExpo 2024 trade fair special (topics, exhibitor news and further information)