Unlike many traditional coatings and fillers, UV-cured materials will not cure on their own until exposed to UV light at a specific wavelength and minimum energy intensity. Photo Credit: Carlisle Fluid Technologies

Q: Why are more collision repair shops using ultraviolet (UV) curing as part of their repair processes?

Speed and efficiency

Repair time per car and cars completed per day are two of the most critical key performance indicators (KPIs) for modern repair shops, and UV curing boosts both. Body fillers, primers and clear coats can be fully cured in as little as 30-120 seconds, versus the 15-30 minutes of traditional heat or infrared (IR)-based methods. UV curing can also be done outside the paint booth, freeing up the most valuable asset in the shop for its primary use.

VOC reduction

UV coatings and fillers do not rely on the evaporation of solvents to bond and harden, resulting in significantly lower volatile organic compounds (VOCs). Some formulations are even 100% solvent free and have zero VOC emissions during curing. This makes hitting ever more stringent VOC regulations significantly easier.

Increased offerings

Coating and body filler manufacturers have significantly expanded their UV-cure range of products in recent years, in large part because of the benefits already mentioned. While in the past it could sometimes be difficult to find an exact UV substitute for your existing product, the breadth of offerings today can cover almost any requirement.

Q: What are the major considerations before making the switch to UV curing?

Curing coverage

Unlike many traditional coatings and fillers, UV-cured materials will not cure on their own until exposed to UV light at a specific wavelength and minimum energy intensity. This means the consequences of “missing a spot” while curing can be severe, as rework of the repair area will almost always be required. Ensuring operators are properly trained to expose all areas of the repair for the minimum required curing time is key to maintaining quality.

Safety

There are two primary curing wavelengths on the market, 365 nm and 395 nm. 365 nm equipment uses primarily older technology and is significantly more dangerous for any exposed skin and eyes. Most modern UV-LED curing equipment uses 395 nm curing, which, because of its closer proximity to the visible light spectrum, is much safer for operators. It is important to select equipment with quality LEDs that emit almost all light at exactly 395 nm, as lower-quality equipment tends to emit across a spectrum of more dangerous wavelengths, which increases safety risks for operators.

Q: What features should I look for in UV curing equipment?

Consistent light intensity

UV coatings and fillers will only cure once the proper light wavelength and energy intensity conditions are met. A common problem with lower-quality UV equipment is that they emit high energy intensity in the center of their light pattern but are very weak around the edges. This increases the risk that the edges of the repair area will not be fully cured, and therefore results in rework. UV equipment that has consistent intensity over the entire pattern, not just in the middle, should be selected.

Consistent power output

Battery-powered UV-LED offerings are popular because of their portability and light weight. However, the battery can become the weak link as its charge is depleted, just like power tools that slow down as the battery dies.. But unlike power tools, because UV light is invisible to the naked eye, an operator cannot tell that the UV equipment is now emitting less power and will require more time to fully cure. You should select equipment with purpose-built batteries that provide consistent amperage from full charge to depleted, so your operator doesn’t have to adjust their curing process based on battery charge.

About the Author

Photo Credit: Carlisle Fluid Technologies

Jacob Fortmeyer is the Auto Refinish SBU Director for Carlisle Fluid Technologies. Visit carlisleft.com.

Fast-paced manufacturing applications require quick-drying coating solutions — coatings designed for force-dry applications can reduce the risk of parts sticking together. Source: Cortec Corp. 

Q: What coatings are recommended for meeting force-dry, high slip or high temp requirements?

A: In addition to good adhesion and rust prevention, a metal coating must be equipped to meet force-dry, high slip, or high temp requirements in certain applications. While it would be difficult to list all of the industrial applications where force-dry, extra slip or high temp coatings could be used, here are a few examples of where such solutions are needed.

Force-dry applications

Fast-paced manufacturing applications require quick-drying coating solutions. Many spray or dip lines move so quickly that the parts pile up at the end of the line. This is bad news if parts are hot and sticky — they could easily adhere to each other and potentially damage the coating when components are pulled apart.

EcoShield 386 FD, which is designed for force-dry applications, reduces the risk of parts sticking together. While this water-based acrylic one coat system can be applied direct-to-metal (DTM) for protection in harsh, outdoor or unsheltered applications, it was specifically designed for fast-paced, force-dry applications, common in manufacturing environments. In addition to outstanding corrosion protection at 1.5-3.0 mils (37.5-75 µm) DFT (dry film thickness), EcoShield 386 FD force-dries in just 5-10 minutes at 150°F (65°C) and has good hot hardness. 

This feature can offer an advantage in manufacturing applications where pipes, hooks, castings, and a variety of other equipment components are made.

Extra slip applications

A protective ID (inner diameter) coating can be critical for new piping stored outdoors or shipped through harsh, corrosive conditions. However, when it comes time to install the conduits, electrical wires must be able to slide easily through the tubing. Electrical conduits are a good example of where a slip coating such as EcoShield VpCI-386 HT can be beneficial. The direct-to-metal, water-based topcoat helps allow the wires to move through the tubing while also inhibiting corrosion.  

EcoShield VpCI-386 offers excellent corrosion protection at 1.5-2.0 mils (37.5-50.0 µm) DFT. It is heat resistant up to 500°F (260°C) or more (depending on color) and improves surface slip. The coating is thixotropic and resists sagging and running during application.

The same benefits would apply to other metal surfaces, parts, or equipment in need of a protective coating that is slippery.

High temp applications

In addition to needing extra slip, electrical conduits are a great example (although by no means the only example) of a high temp application. These pipes start out as flat pieces of metal that are rolled into tubes, welded and internally painted before the welding heat can cool down. EcoShield VpCI-386 HT Slip Coating is designed to withstand this extra heat during coating application and similar high heat curing processes. It can also be used on equipment that may reach temperatures up to 500°F (260°C) during operation.

Anticorrosion coatings with additional features

While the main purpose of a coating may be to protect metals from corrosion, many manufacturing applications may introduce additional special requirements, such as force drying, extra slip or high temperature resistance. Make sure to weigh all considerations when selecting a coating to stand up to these demanding applications. 

*Special thanks to subject matter expert Rick Shannon for technical support on this topic.

About the Author

Julie Holmquist

Julie Holmquist is a content writer for Cortec Corporation. Visit corteccoating.com.

Atotech, an MKS brand, presents a high-performance coating process that reduces energy consumption and CO₂ footprint.

Zintek 400, a zinc flake coating that can provide greater than 2,000 hours neutral salt spray protection on large components, can be used with XLink 800, a cross-linking technology that enables the coating to dry/harden at ambient temperature. 

The pretreatment process includes a low-temperature, long life cleaner, near neutral pH descale, zirconium pretreatment and ambient temperature adhesion promoter. 

This latest coating process in the Atotech CP3.0 program expands the scope of applications that can use zinc flake coating technology.

Plant 72, which is a 244,000-sq.-ft. building, houses an ecoat line, a powder coating line, a wet paint line and offers de-rusting and pickling as well as top coating and chemical agent resistant coatings (CARC). Photo Credit: Lippert

A business that is highly tuned in to market trends and its customers’ needs is one that is wise enough to adapt accordingly. Lippert, a metal fabrication company in Mishawaka, Indiana, that primarily serves the RV industry, is one of these companies. Its Plant 72, the company’s main coatings facility, has shifted from painting RV components to coating jobs outside the RV realm, including those in the automotive, military, agriculture, construction and aerospace industries. The company’s outreach over the last 4 years has not only diversified its customer base but has enabled it to become less affected by the volatile RV market.

“Instead of being a 95% RV company, which we were 6 or 7 years ago, we’re about 60% RV now,” says Joe Thompson, general manager at Lippert. “At this point, 40% of our market is outside of our core business.”

Opening doors to different industries has helped company management realize that Plant 72 offers coatings capabilities to many businesses that do not have access to paint facilities otherwise.

The EV customer attraction

Lippert has many coatings capabilities across its facilities for its internal RV component work. However, coatings are Plant 72’s main focus, and it is the only facility that pursues outside business. The company originally acquired it 10 years ago to help with capacity needs for its RV customers. But with the fluctuation of that specific industry, it has been able to move those in-house jobs out of Plant 72 and into its other buildings that have the capacity to support it.

Plant 72, Lippert’s main coatings facility, has shifted from painting RV components to coating jobs outside the RV realm, including those in the automotive, military, agriculture, construction and aerospace industries. Photo Credit: Lippert

With this available capacity, the coatings plant, which completes a lot of Tier 2 and 3 jobs with quick turnaround (three to five business days), is especially attractive to the electric vehicle (EV) market. According to Thompson, the EV industry is racing to get these vehicles on the market as fast as possible.

“They need a facility like what we have (with a large ecoat capacity) to be able to do this,” he says. “Our customers can’t put up a facility overnight, but they are trying to get components out the door that fast. It is an interesting advantage for us.”

Plant 72, which is a 244,000-sq.-ft. building, houses an ecoat line, a powder coating line, a wet paint line and offers de-rusting and pickling as well as top coating and chemical agent resistant coatings (CARC). The facility has the capacity and equipment to perform multiple coating processes in a single building, which streamlines the production process.

Its ecoat line, affectionately called “El Chingón” by the plant’s team, is the largest non-captive ecoat system in North America, according to Thompson.

El Chingón

A Spanish term referring to something that has much power, Plant 72’s El Chingón is an indexing ecoat line that offers cathodic acrylic and cathodic epoxy coatings with an eight-stage zinc phosphate pretreatment cleaning system, which is U.S. Department of Defense-approved and meets military CARC specifications (T-TC-490E Type 1).

Plant 72’s “El Chingon,” the company’s huge ecoat line, is said to be the largest non-captive ecoat line in North America, with dimensions at 50' long x 9' deep x 63" wide. The equipment offers an eight-stage zinc phosphate pre-treatment cleaning system as well. Photo credit: Products Finishing

Thompson describes the machine’s specs. “The load bars that are carried through the index can handle 6,000-lb. max part weight at one time or 2,000 sq. ft. of product, whichever maxes out first,” he says. “Each of the eight pretreat tanks are 50 ft. long, 10 ft. deep and 65.5 inches wide. The tanks can hold up to 30,000 gallons of product.”

The cathodic epoxy offered has 1,000-plus hours of salt spray resistance. The cathodic acrylic can withstand up to 750 hours of salt spray resistance and UV protection. Its pretreatment and epoxy ecoat meet most automotive and military specifications.

Powder coating and more

Plant 72’s powder coating line is a standard system with manual powder guns that can do quick color changes with multiple colors available. The line, which also has a zirconium pretreatment system that stands in front of it, is 15 ft. long by 3 ft. wide by 6 ft. tall.

Lippert offer a variety of powder coating color options and can accommodate products up to 10' long, 5' deep and 2' wide. It also uses a NT-1, five-stage cleaning process on all its products. Photo Credit: Lippert

Although the capacity of this powder coating line does not match the large capacity of the plant’s ecoat line, Thompson says Lippert has plans to build a powder coating facility nearby that matches it.

Fortunately, the company owns nine powder coating facilities all within the vicinity of Plant 72 that can match the capacity of its ecoat line. Therefore, when the demand arises for a large part to be powder coated, the plant will ship the work to one of these other facilities to finish the job.

All coated parts are force cured at the plant. “We have an enormous oven for ecoat, and other ovens for the powder coat and wet coat processes,” Thompson explains.

Other capabilities that the facility boasts include a wet coat line — which sprays wet paint that is 20 ft. long by 5 ft. wide by 10 ft. tall — light assembly, packaging and shipping.

Boxing and blasting

Because Lippert understands that value-added opportunities are becoming increasingly critical to stay competitive, the company is doing light assembly as well as boxing and labeling of service parts for its automotive and military customers.

“This (in-house shipping operation) has been a growing market of ours,” Thompson explains. “Most manufacturing facilities don’t want to shut down their coating lines for their service parts. So, we’ve become a one-stop shop here where we box them up, and they’re ready to go wherever the need is.”

Bringing the packaging and labeling process in house is one example of how Plant 72 is constantly devising paths to improvement. Staying abreast of the latest equipment or processes in the industry is another way. When management realized that implementing a blasting system would be advantageous for its customers, it began planning for the installation of a media blasting booth, which is currently underway. The blast booth matches the plant’s ecoat capacities; it stands at 60 ft. long by 10 ft. wide by 10 ft. tall.

Predictive maintenance

With a large, 30-year-old machine like El Chingon, Plant 72 has learned that nonstop maintenance of this equipment is the key necessity to keeping it and the business running smoothly.

All coated parts are force cured at the plant. It has an enormous oven for ecoat, and other ovens for the powder coat and wet coat processes. Photo Credit: Products Finishing

“To be able to maintain that and stay in front of it has been a huge feat,” Thompson says. “We cannot afford to have our equipment go down, so we stay on top of that game.” He adds that even a little downtime is problematic because the ecoat line produces so much work, and it is a costly investment to keep it running.

However, Thompson gives credit to the predictive maintenance systems that the company has been putting in place. Also, the facility’s attentive team changes out parts before they fail instead of after, when it is too late.

On the horizon

While Lippert is busy predicting maintenance for its equipment, its management is also doing its best to predict the future market trends that will affect its business.

Although the RV market benefited from the COVID pandemic where it saw a boom in sales, 2023 was a hard year for the industry. It faced a heavy slowdown then, but according to Thompson, the company believes it has seen the bottom of it. “It is starting to pull out, but I don’t think this year we will hit the numbers we did during COVID — it was tremendous,” he says.

Like the RV industry, the marine market (of which Lippert is an OEM supplier) boomed during the pandemic but is slowly bouncing back, Thompson says. With spring around the corner, the company is prepared for business to pick up in that area.

With demand for coatings in many different markets, Lippert has plans to expand its coatings presence, especially in the south. Thompson says the company would like to open a new facility there with ecoat and similar capabilities and capacities to what Plant 72 offers.

“We’ve figured out how to be successful in coatings, and how to make it a financially viable business unit, and also partner with people with that need which opens doors for us across the rest of our business,” he explains.

Dürr showcases its new EcoSupply P Core paint supply system at Paint Expo 2024 in Karlsruhe, Germany.
Source: Products Finishing

Dürr (Southfield, Mich.) introduces the EcoSupply P Core, a revolutionary modular paint supply system built on pigging technology, marking a significant advancement beyond its successful implementation in automotive painting. Now adaptable across various industries, including construction, woodworking, and automotive suppliers, the EcoSupply P Core efficiently handles the application of different paint colors in small quantities while minimizing waste and optimizing color changes.

Pigging technology reduces paint and rinsing agent consumption by returning the paint left in the hose after application to the paint container.
Source: Dürr

The demand for diverse color options transcends automotive needs, with industries like construction and plastics relying on a spectrum of shades to meet customer preferences. However, traditional paint supply systems incur significant losses in paint and rinsing agents during color changes, leading to increased costs, especially with minimal quantities.

The source station (shown here) is the pig’s starting point. The material pushes the pig from the source station through the distributor station to the destination station.
Source: Dürr

Dürr's innovative pigging technology revolutionizes the process by utilizing specially designed "pigs" to optimize efficiency and reduce consumption of paint and rinsing agents. The pig, fitting snugly within the hoses, facilitates the transfer of paint while removing any residual rinsing agents. This streamlined process enables faster color changes and simplified maintenance, with the EcoSupply P Core available in both single-pass and circulating versions, suitable for water and solvent-based paints.

The modular design of the EcoSupply P Core allows for flexible configuration and integration with existing systems, offering a seamless solution tailored to user requirements. Dürr's starter kit includes all essential components, along with sensors for monitoring and maintenance tools, ensuring a comprehensive and user-friendly experience. 

The sales launch for Dürr's EcoSupply P Core is planned for early summer.

The Association for Materials Protection and Performance (AMPP), the global authority in materials protection and performance, has annnounced a donation from the PPG Foundation for the EMERG Programs to support students in the coatings industry.  

The contribution will support the expansion and development of several EMERG programs designed to foster education and innovation in coatings and corrosion. Among these initiatives are academic scholarships, the provision of Corrosion Toolkits (cKits), and the organization of a mini-camp for high school students at the AMPP Annual Conference + Expo in New Orleans, March 3 – 7, 2024.

The EMERG (Engage, Magnetize, Educate, Raise, Guide) initiative by AMPP is a comprehensive life-cycle approach to engage students at all educational levels with the fascinating world of materials protection and performance. From primary school students to veterans and adults transitioning into the industry, EMERG offers a range of opportunities, including scholarships, educational resources like the innovative cKit, and interactive mini-camps that provide hands-on learning experiences.

“Supporting AMPP’s EMERG programs and the diverse students they serve is an investment in the future workforce of the industries where PPG operates,” says Malesia Dunn, executive director, PPG Foundation and corporate global social responsibility. “We believe that by engaging students early in their educational journeys, we can inspire a new generation of scientists, engineers, and professionals dedicated to advancing the field of materials protection and performance. We recognize the importance of this donation in providing students with a hands-on, practical education that arms them with the advanced skills needed for their careers.”

The cKit, developed by AMPP’s top corrosion experts, serves as a dynamic educational tool for high school teachers to demonstrate corrosion concepts in an engaging manner. It includes all necessary materials for experiments, making science accessible and enjoyable for students. Additionally, the EMERG Student Camp, held during AMPP’s annual conference, allows students to explore the practical applications of their studies through corrosion experiments and interactions with industry professionals.

The EMERG academic scholarships recognize and support students with exceptional academic achievement in coatings and corrosion. By offering these scholarships, AMPP and its partners aim to alleviate financial barriers for students pursuing careers in this critical industry. This is the eleventh year of PPG’s support of AMPP scholars. 

“Through initiatives like EMERG, we aim to create a continuous cycle of engagement, education, and professional development that not only supports students but also enriches our industry as a whole,” says Kim Ray, Director of the EMERG Student Outreach Program. 

PPG has launched its Nexeon 810 coating, a copper-free antifoulant developed with an emphasis on vessel performance, emissions reduction and sustainability. The company claims that the surface of the coating can yield a boost in power and enhance operational efficiency because of improved fouling control performance, depending on the vessel and operating conditions.

Furthermore, the company asserts that using Nexeon 810 coating reduces fuel consumption and lowers greenhouse gas (GHG) emissions, enabling a vessel to sustain higher speeds while helping vessel owners and operators remain compliant with the carbon intensity indicator (CII) requirements of the International Maritime Organization (IMO). The coating’s formula can reportedly achieve a total reduction of up to 25% in GHG emissions compared to traditional antifouling coatings and supports 60 days of idle time resistance with minimal speed loss.

The coating is designed to offer controlled and predictable solubility, to promote strong performance throughout the vessel’s operational period. The coating is also suitable for electrostatic application and offers color retention throughout the service life of the vessel.

“PPG Nexeon 810 coating provides the ultimate combination of advanced coatings technology with improved vessel performance and responsible environmental protection,” says Joanna van Helmond, PPG global product manager, antifoulants, protective and marine coatings. “Thanks to PPG’s sustainably advantaged product development process, our customers can enjoy easier application and improved coating performance across the operating life of their vessels.”

The copper-free technology in Nexeon 810 coating is characterized by a reduced biocide content. PPG says its binder technology enables the gradual release and operation of the biocides near the surface, and upon entering the water, the combined effects of sunlight and ocean bacteria kickstart the breakdown of these organic biocides.

The potential for electrostatic application is a significant benefit that the company says is not available in conventional antifouling coatings. The transfer efficiency achieved through electrostatic spraying reportedly provides a uniform film as well as a decrease in overspray and waste, resulting in a reduction in paint consumption and improved health and safety benefits when compared to airless spraying.

Triplex Plating CEO Jamie Baldwin and COO Jesse Baldwin received the 2023 Top Shops award for Plating/Anodizing at SUR/FIN 2023.
Source: Products Finishing

Products Finishing’s 2024 Top Shops Benchmarking Survey is now open as of February 1. The annual program was created to aid finishing shops in measuring their key operating metrics and assessing how their business compares to others in the industry.

Each year the Top Shops program takes its core mission of continuous improvement to heart, seeking ways to further improve the benchmarking survey and the resulting reports. This year, the Top Shops program offers a fresh approach tailored to meet the needs and time constraints of industry professionals. This year’s surveys are designed to offer participants the benefits of benchmarking and recognition without overwhelming them with an exhaustive list of questions.

Core questions offer simplified but cohesive approach

Recognizing the value of finisher’s time, Gardner Intelligence has revamped its survey structure for 2024. The survey’s core questions, constituting fifty percent of the survey, are tailored to provide valuable insights to the majority of participants. Respondents are urged to complete the core survey by April 30, 2024, to receive a customized benchmarking report, and the chance to earn Top Shops status, and be recognized as an honoree.

Digging deeper

After completing the core survey, participants can opt-in to modules of additional benchmarking questions, delving deeper into specific aspects of their operations. Whether it’s profiling, operations, technology, business strategy, or human resources, participants have the flexibility to select modules based on their business priorities.

Why Participate?

Participants in Top Shops benchmarking program receive a customized report showing how their responses compare to other facilities. This allows participants to better assess strengths and weaknesses, and to determine areas for future improvement. In addition, companies that rank in the top 20% of scores are recognized as Products Finishing Top Shops and celebrated in Products Finishing magazine, through PF’s various media channels and at industry events. 

The Coil Coatings division of Sherwin-Williams (Minneapolis, Minn.) has released a collection of printed metal coatings colorways, Emulate, for product and design professionals. The collection derives inspiration from mimicking the beauty of nature and aims to bring an enhanced look of natural building materials in wood, stone and metal to enable architects and product manufacturers to complete their vision in a new way. 

The collection uses a solid base coat and layers of ink that can be created with unique patterns and rich multi-layer effects. By utilizing a rotogravure printing process, these coatings are applied with an impression roller for the desired look of nature to the metal substrate.  

“Our experts at the Sherwin-Williams DesignHouse studied design trends, nature and countless products across markets,” says Kiki Redhead, Global Color Materials Finish (CMF) & Trend Manager at Sherwin-Williams. “While observing the evolution of wood, natural metal and stone, we realized an opportunity to create something that would simultaneously stand out and fit in.” 

According to Sherwin-Williams, Emulate mimmicks the design, pattern and structure of common building materials and the latest offering includes 30 total colorways across specific collections for wood, stone and metal. 

The company goes on to say that the colorways not only add beauty to a project, but they do so without stripping the world of finite natural resources — part of Sherwin-Williams sustainability commitment to preserving the environment with recyclable metal substrates. 

“For example, in a very intentional way, we’ve been able to mimic the beauty and detail of wood while providing design flexibility and durability,” says Brynn Wildenauer, Architectural Color Designer for Sherwin-Williams Coil Coatings. “Similarly, by mimicking the finishes of natural metals such as zinc and copper and heavy stone, architects can achieve the desired look these precious building materials offers, but in a much more efficient way.”  

The Coil Coatings team has translated the technologies, colors and effects of Emulate based on market research and major societal catalysts such as sustainability, economy, humanity and equality. The offering is informed by Sherwin-Williams color and coating experts, leveraging years of research and development to present colors and effects intended to inspire architectural and building product design. 

Spray Tech Industrial Solutions and PBS Industries have merged to create a new entity, Combined Finishing Company. The merger brings together the specialized expertise of Spray Tech Industrial Solutions in cutting-edge spray coating technologies with PBS Industries’ expertise in industrial ventilation equipment solutions and extraction rooms. 

The merger gives PBS Industries and Spray Tech a combined 80+ years of experience in the finishing industry and will provide a variety of options and greater service for customers. Benefits include:

• An expanded service portfolio that covers every aspect of finishing solutions and industrial ventilation equipment and extraction rooms, and ensures access to a variety of products, as well as maintenance technicians for booth equipment.
• Enhanced efficiency translating into quicker turnaround times and streamlined project delivery.
• Access to the collective expertise of both companies.
• Innovation and Adaptability: The joint entity is poised to stay at the forefront of industry trends, incorporating the latest technologies and best practices to offer innovative solutions that meet evolving customer needs.

Jeff Behymer, president of Combined Finishing Company, says, “By combining our companies, we can provide our customers with a single source for everything service and equipment related for their finishing needs. Both companies had plans to expand, making it a no-brainer for the two companies to merge and provide customers with broader service options and products.”

Cliff Smith, Vice President of Operations, adds, “By combining our resources, we can provide better service and support our customer’s finishing needs on a broader scale.”

Combined Finishing Company headquarters is located in Oklahoma City, Oklahoma. The company will continue to provide services across the nation.