Towards PaintExpo 2022: profitable and sustainable solutions
To ensure that components coated with various coating technologies would ultimately exhibit a flawless finish, FreiLacke developed its system coating concept a few years ago. Factors such as sustainability, energy efficiency and climate protection have also played an increasingly important role in development. In this context, the system coatings manufacturer also continued the developments of powder, liquid and electrodeposition coatings and composite solutions, while simultaneously unveiling solutions for the wind energy and rail vehicle sectors.
Components and parts are increasingly manufactured globally before eventually being assembled locally and fully or partially coated with different coating systems. Therefore, the individual parts must not only be perfectly compatible, they must also have a homogeneous and consistent overall appearance with regard to color, gloss and surface structure.
Meeting these demands while maintaining or improving quality standards despite increasingly stringent VOC regulations and faster cycle times requires application solutions.
Coordinated coating technologies
This is where FreiLacke system coatings come into play: With its system coating concept of powder and liquid coatings, EC and composite solutions, the coating specialist from the Black Forest focuses resolutely on uniform surfaces, whatever regardless of systems, application processes and facilities. implied. Customers with different production sites, sometimes even located on different continents, are already using the system coatings with great success.
“As a manufacturer of coating systems, we have the means to perfectly coordinate coatings during product development and production.
“Therefore, not only can we offer our customers all major coating technologies, but we are also able to optimally match them in terms of coating structure and finish to provide a suitable solution, meet the conditions- stipulated frameworks and ensure profitability and sustainability.”
Against this backdrop, FreiLacke is unveiling a variety of further system concept developments in all four product areas at this year’s PaintExpo.
CE no labeling requirements for greater durability
Aspects such as sustainability and VOC reduction have long been priorities for the coatings manufacturer and are one of the main reasons for the continuous extension of the range and the development of new solutions at the Döggingen/Black Forest site. An example is the ‘EcoOne’ electrodeposition coating, a two-component (2K) system free of solvents and neutralizing agents requiring labelling. The system is environmentally friendly and does not affect the health of employees. What is also exceptional with FreiLacke EC systems is that they are energy efficient. The required firing temperature of the coating is approximately 30°C lower, which equates to considerable energy conservation in the combustion process. An outstanding uniform coating film that reliably protects the metal component is nevertheless obtained. The coating layers are mechanically strong and visually flawless.
Powder coatings: cost-effective, durable and eco-efficient
The range of environmentally friendly powder coatings from the established Black Forest company has also been constantly expanded. The product portfolio includes a broadly diverse selection for application areas such as steel and alloy wheel production, the automotive industry, mechanical and device engineering as well as the wind power industry and the utility sector. rail vehicles. In particular, solutions for large and bulky components that dispense with the firing process accentuate the cost-effectiveness and sustainability approach.
FreiLacke powder coating on metal
Solutions have also been developed to address the challenge of seamlessly distributing the thickness of the powder coating layer over sophisticated geometric parts, which is often only possible to a limited extent in order to adequately cover undercuts or cavities, other areas of the component often have denser layer thicknesses.
“In the case of conventional fine-textured powder coating systems, this means that the denser layer thickness will exert an optical influence on the structure or even cause the powder coating layer to foam. Ultimately, this leads to defective goods or expensive extra work. »
However, with the new PP5011A product line, FreiLacke has succeeded in countering this problem: even with layer thicknesses well above those specified in the data sheet, the surface will remain uniformly flat; this means that the surface structure in the range between 80 and 160 μm is very homogeneous. This has enabled the coatings specialists at FreiLacke to successfully provide processors of automated coating systems and manual coaters with significantly greater flexibility and reach when it comes to coating their components with fine-textured powder coatings.
In the case of low temperature (NT) powder coating, the baking temperature can be significantly lowered and the heating energy consumption significantly reduced. NT coatings also help to significantly reduce oven dwell time and therefore increase conveyor speed. FreiLacke also successfully continued its development in this key area.
Powder coatings are also a suitable option for coating materials such as SMC/BMC as they are simply sprayed into the mould. The highly reactive coating cures in seconds, allowing the SMC/BMC to be immediately placed and pressed. After pressing, the finished coated component can be demolded as usual. Surfaces generated by the PIMC process exhibit excellent chemical and mechanical resistance and are well suited for continuous outdoor use. The material is free of solvents, hazardous substances and carcinogenic raw materials. PIMC is flame retardant according to EN45545, HL3, R1 and thanks to its good properties it can be used for many applications – for example kitchen sinks, shower trays, facades, lighting fixtures, sports equipment or in vehicle construction.
A major advantage of this process: By combining pressing and coating in a single work step, the laborious subsequent coating (including handling of the associated parts) can be eliminated, as well as the extensive logistics required when transporting the components to the factory for internal coating or for external coating. When using the PIMC process, components remain in-house until they are completed and can then be shipped immediately to the customer. Another advantage: added value for operators and lower costs and better quality for customers.
Liquid coatings: from filler to topcoat
FreiLacke liquid coatings offer highly effective solutions for surfaces in industrial applications. Whether subject to corrosion, chemicals or weathering, FreiLacke provides the optimum protective coating for substrates such as steel, stainless steel, galvanized substrates, aluminum and plastic. Liquid coatings are used at all levels of the coating structure: as primer or filler, basecoat or topcoat as well as in one-coat systems. Industrial coatings are available in a variety of finishes and gloss levels for interior and exterior.
FreiLacke Liquid Coating will be presented at PaintExpo 2022
Increasingly stringent requirements for surface coatings and the continued reduction in VOC content of paints and coatings have led FreiLacke to develop Ultra High Solids (UHS) systems. For conventional coatings, completely new coating systems with a solids content of up to 80% by weight and a VOC value of less than 350 grams per liter have been developed and brought to series maturity. They facilitate rapid drying and accelerated production processes. FreiLacke therefore has different one- and two-layer solutions that offer high resistance to this effect. The coatings are available in all RAL colors as well as in special colours. Easy application – whether pneumatic, Airmix, Airless or ESTA – and excellent resistance levels set this system apart.
PaintExpo will also see FreiLacke unveil its FreoCure extremely fast-curing liquid coating system to industry visitors for the first time.
Cleverly crafted composites
The advantages of glass and carbon fiber reinforced composites (GRP/CRP) are obvious: they are lightweight, extremely durable and can be molded into almost any shape. In addition to a diverse range of surface coating materials, FreiLacke now also supplies components for the manufacture of parts. An example is the new CM powder technology. Thanks to a special two-step principle, this innovative composite powder differs from conventional composite material resin systems in that it can be melted without starting the curing process.
FreiLacke offers numerous coating solutions for composite materials, ranging from color pastes and fillers to gelcoats. These are durable, colored coatings that are applied directly in the mold and provide castings with long-term protection against moisture, UV rays and impact damage.
Coating system specialists have also succeeded in significantly reducing the percentage of styrene in gelcoats as the substance is considered hazardous to health and problematic for the environment.
“Using an alternative monomer, we have made a gel coat with reduced styrene content that provides even better results than conventional systems in terms of weather resistance and shelf life.”
For components susceptible to increased erosion, such as wind turbine rotor blades, coating professionals provide Leading Edge Protection (LEP) high performance edge protection coating. The novelty of the range is a modular production technology that no longer disperses, but homogenizes. Modular coating recipes include liquid components that can be dosed fully automatically and are produced faster to respond quickly to customer demands.
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This article was originally published by FreiLacke.